Processing Poultry to Harvest Meat

Feed withdrawl

Broilers are kept off-feed 8-12 hours preslaughter to reduce fecal contamination risk during processing and evisceration; results in inherent weight shrinkage

Live catching & crating

Birds must be caught carefully, with proper technique (by both shangs or by the breast with both hands) to minimize distress, damage (bruising) and injury; mechanical/automatic harvesters utilized alternatively

Live catching conditions

Light intensity and ventilation (avoid heat stress) must by managed

Transportaion

Transport modules must adhere to local legislation; vehicles should not be overfilled to prevent over-heating, bird stress, mortality and high rates of condemnation at processing plants; suitable vehicles with proper ventilation and extra heating/cooling must be used for adequate environmental protection; stops, distances, and transport time must be minimized

Holding

Birds must be held in a cool, weather-proofed area upon plant arrival; humidity, temperature, and bird comfort must be routinely monitored preslaughter

Age, sex, housing temperature, eating patterns, transport time, and holding temperature

Pre-processing weight loss factors

Shackling

The hanging (upside down) of birds from shackles to an automated processing line

Stunning

Electric current is delivered through a waterbath or electric knife to deem bird unconcious during slaughter; current must be compliant with minimum recommended for the specific bird; gas stunning (CO₂ immersion) can be done alternatively

Bleeding

Birds are pased through an automated knife that makes an incision to the jugular vein following stunning; blood is drained from the carcass

Scalding

Submersion of carcasses in water heated to 150°F, loosening the feathers’ connection to the skin

Picking

Feather removal; automated machine contains rubber finger-like projections to rotate and defeather the carcass without damage

Limb removal

Feet, head, neck, and oil glands are removed with pneumatic shears

Evisceration

Removal of internal organs

Inedible viscera

Consists of the spleen, esophagus, lungs, intestines, and reproductive organs

Edible viscera (giblets)

Consists of the heart, liver, and gizzard

Condemnation

Removal of a carcass from the processing line if an identified disease or other problem is found during inspection

Carcass washing

Carcasses are cleaned for microbial and visible concerns (E. coli and Salmonella analyzed)

Chilling

Carcass temperature is reduced to a USDA specified temperature/time to prevent microbial growth; usually submerged in an ice bath but can be air chilled

Cut-up and deboning

Carcass is solde whole or individualized by component for individual sale; bones can be removed from cut-up meat

Dressing percentage (carcass yield)

Amount of live weight retained in the carcass