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1. Process flow of poultry
processing
Presented by: Faryad Ali
2017-ps-030
Presented to: Dr. Sher Ali

2. Contents
Receiving
Slaughtering
• Stunning and killing
• Scalding
• De-feathering
• Removal of head and legs
• Evisceration and inspection
chilling

3. Receiving
• The birds are removed from the cages and transferred to continuously moving
shackles where they are suspended by both legs. The transfer is often done in a
dark room illuminated by a red light.
• The birds are not sensitive to the red light and this helps to keep them calm.

4. Slaughtering
• Slaughtering refer to killing of domestic livestock. The slaughtering involves some
initial cutting, opening the major body cavities to remove the entrails.
• Slaughtering is done by two methods;
 Traditional method
 Modern method

5. Traditional methods
• HALAL:
• The Islamic form of slaughtering poultry, involves killing through a cut to the jugular vein, carotid
artery and windpipe.
• Muslim method of slaughtering.
• No blood should be left in carcass.
• JHATKA-
• Practiced by Sikhs.
• Head is completely removed in one stroke.

6. Cont…
Kosher:
• A Jewish method, Only sheep, goat, deer, cattle and poultry slaughtered.
• Meat should not contain any blood vessel
• Meat should not be preserved for more than 3 days.

7. Stunning and killing
• After the birds have been transferred to the moving shackles, they are usually
stunned by running their heads through a water bath that conducts an electric
current.
• It is also done by giving carbon dioxide.
• Stunning produces unconsciousness, but it does not kill the birds.
• The birds are killed either by hand or by a mechanical rotary knife that cuts the
jugular veins and the carotid arteries at the neck.
• The birds are permitted to bleed for a fixed amount of time, depending on size and
species (e.g., 1 1/2 minutes for broilers).

8. Cont…
• The birds are permitted to bleed for a fixed amount of time,
depending on size and species (e.g., 1½ minutes for broilers).

9. Scalding
• Scalding Following bleeding, the birds go through scalding tanks. These tanks
contain hot water that soften the skin so that the feathers can be removed.
• The temperature of the water is 50-55 °C for 1-3min.
• Turkeys & spent hens ( egg-laying birds that have finished their laying cycles) are
generally run at higher temperature- 59 to 60°C for hard scalding.

10. Defeathering
• The carcasses then go through the feather-picking machines, which are equipped
with rubber fingers.
• An extra process, called wax dipping, is often used for waterfowl, since their
feathers are more difficult to remove.
• Following the mechanical feather picking, the carcasses are dipped in a melted,
dark-coloured wax.
• The wax is allowed to harden and then is peeled away, pulling out the feathers at
the same time. The wax is reheated and the feathers are filtered out so that the wax
can be reused. This process is usually performed twice

12. Removal of head and legs
• The heads of the birds go into a channel where they are pulled off mechanically,
the legs of the birds are removed with a rotary knife (much like a meat slicer).The
carcasses drop off the shackle and are rehung by their hock onto
the eviscerating shackle line.

13. Cont…
• By law in the United States, the scalding and defeathering steps must
be separated by a wall from the evisceration steps in order to minimize
cross-contamination

14. Evisceration and inspection
• At this point the preen, or oil, gland is removed from the tail and the vent is
opened so that the viscera (internal organs) can be removed.
• Evisceration can be done either by hand (with knives) or by using complex, fully
automated mechanical devices. Automated evisceration lines can operate at a rate
of about 70 birds per minute. The equipment is cleaned (with relatively high levels
of chlorine) after each bird.
• The inspection procedures in the poultry industry vary around the world and may
be performed by government inspectors, veterinarians, or plant personnel,
depending on a country’s laws.

17. Chilling
• After the carcasses have been washed, they are chilled to a temperature below 4
°C (40 °F). The two main methods for chilling poultry are water chilling and air
chilling.

18. Water chilling
• In which a countercurrent flow of cold water is used to lower the temperature of
the carcasses.
• it is common to employ long chillers (e.g., 10- 50 m long) that use a counter flow
of cold water, sometimes supplemented with crushed ice, to bring carcass
temperatures to about 4 - 5°C within 30 - 75 min.
• The carcasses are then moved into a chiller
• Two tanks are used to minimize cross-contamination.

19. Cont…
• Water chilling leads to an increase in poultry weight. In the United States the legal
limits for water pickup are 8 percent for birds going directly to market and 12
percent for birds that will be further processed.

20. Air chilling
• The carcasses are hung by shackles and moved through coolers with rapidly
moving air. The process is less energy-efficient than water chilling, and the birds
lose weight because of dehydration.
• Air chilling prevents cross-contamination between birds. However, if a single bird
contains a high number of pathogens, this pathogen count will remain on the bird.
Thus, water chilling may actually result in a lower overall bacterial load, because
many of the pathogens are discarded in the water.