Defeathering Machine Research Articles

Design and Implementation of a High-efficient Chicken Defeathering Machine for Commercial Utilization

Design and Implementation of a High-efficient Chicken Defeathering Machine for Commercial Utilization

Development and Performance Evaluation of a Poultry Bird De-Feathering Machine

Poultry birds de-feathering has a daunting challenge. This study aimed at developing a low cost poultry de-feathering machine (DM) that will promote food hygiene; and the safety of operators. The machine consist of a hard plastic drum on which rubber pluckers were fixed and was powered with a 1.5kW electric motor. The DM was developed according to engineering design and principles. The test was achieved by considering the weight of the poultry birds (PB) before and after the de-feathering process. The de-feathered PB weight; and the time taken to de-feather PB were recorded. The feather was discharged through the DM outlet by gravity and weighed to determine the actual weight of the removed feather. The test was repeated five times and the outcome of the recorded results was presented in graphs and tables. Brown old layers (hens) were used for the machine performance evaluation at 7 different scalding temperatures (50, 55, 60, 65, 70, 75, and 80) °C. The DM was designed to de-feather 5 hens per batch. From the result obtained, 5 hens with a total average weight of 9.5 kg de-feather in 28 seconds at 92% efficiency average. The force required to de-feather hens decreased with an increase in the scalding temperature. At a scalding temperature >800 C, the bird skin will pill and give it a rough appearance.

Development and Performance Evaluation of a Rubber and Canvas Strip Fingers Defeathering Machine

Human labour requirement in poultry products processing has continued to increase and more demanding, especially defeathering which is faced with faced challenges such as lacerations and hygiene in handling. To solve these challenges, mechanical defeathering proffered a solution, which further posed a problem of equipment cost and efficiency of operation. This paper investigated a developed a low-cost axial-loading (horizontal) defeathering with dual fingers for small and medium-scale poultry processors. This study reported the development of a defeathering machine which comprises of an axial defeathering drum with strip fingers, which flaps on the carcass to pluck off feathers in motion. The machine is electrically powered with a defeathering power requirement of 0.304 kW and at a power rating of 0.269 kW. The performance evaluation carried out with a broiler, cockerel and layer birds at a soaking temperature of 80 degree Celsius for an average time of 1 minutes showed that the efficiency and the effectiveness of the machine varies with respect to the quality of cleaned carcass produced. It was also observed that it takes the machine about 60 seconds to completely defeather a broiler of 2.4 kg weight, 70 seconds to defeather an old layer breed of bird of about 1.2 kg weight and 105 seconds to defeather a 1.3 kg weight of local chicken. However, test carried out on local birds showed that the machine was less effective defeathering local chicken at low temperature, because of the toughness of the skin. Comparatively, canvass (leather) fingers have the highest defeathering efficiency while rubber strip fingers produced the least defeathering efficiency. Therefore, canvas (leather) strip finger performed better than rubber strip fingers.

Factor Analysis of Poultry Birds De-Feathering Machines

Some concerns had been expressed over the success rate of the De-feathering machine (DM) in Nigeria. Therefore, it is imperative to evaluate DM in selected poultry farms in Ekiti State, Nigeria, and consider the factors that inhibit their viability. This study seeks to verify the success rate and identify factors that pose challenges to DM and provide a solution to their intercorrelations. Kendall Coefficient of Concordance (KCC) and Principal Component Analysis (PCA) was the design framework used to investigate the identified factors that influence DM. The KCC was used to analyse the data matrix generated by 12 Judges who ranked the twenty-eight identified factors that influenced DM in ascending order, upon which basis an index of concordance in ranking among the judges was computed as w = 0.70. PCA was used to further analysed questionnaires crafted with the twenty-eight well-ordered factors, purposively selected, using statistisXL version 2021.2 software. Also, the result obtained by PCA indicates that factor reduction was achieved from twenty-eight variables to seven clusters using a scree plot graph. Furthermore, Cost of Material cluster 5 (consisting of dual factors; ‘stainless steel’ and ‘material selection’) wielded the highest factors loading of 0.847 and 0.779 respectively. This study has helped to justify unsatisfactory DM operating costs among poultry farmers in Nigeria and clarify challenges associated with the high cost of material selection in DM design.

Development of Chicken (Gallus gallus domesticus) Defeathering Machine

This study aims to design and fabricate a small scale defeathering machine using food grade materials. The overall dimension of defeathering machine is 1250 mm x 1160 mm x 650 mm and has a weight of 95 kg. The machine was designed to a capacity of 800 heads per hour. The fabricated chicken defeathering machine has defeathering efficiency of 99.01% and defeathering efficacy of 95.85% at angular speed of 348 rpm. The prototype was tested using 28 days old broiler chicken. It is recommended for further evaluation using other types of poultry animals.

Development of Chicken (Gallus gallus domesticus) Defeathering Machine

Because of the increased demand of chicken meat, the non-vegetarians worldwide has imposed big responsibility on poultry chicken processing industry. The chicken defeathering machines were made with different capacities but they still need of improvement. This paper is focused on the fabrication of a drum type small scale chicken defeathering machine. The drum type chicken defeathering machine was made using locally available materials. Design calculations were done to ensure appropriate shaft diameter supporting the rotating plate as this could affect the efficiency of the machine. The drum of the machine was made detachable and inside of it was the riveted ring on drum surface located above rotating plate. In addition to this, the machine was designed with chute that is made of two layers to separate the removal of feathers and waste water. Handle and wheel caster were included for ease handling and transport from one place to another place. The machine was tested using 28 days old broiler chicken.
 The machine was designed based on the identified problems on existing machine available from three local Dressing Plants namely Poultry Processing Plant in Municipality of Talavera, Nueva Ecija, Poultry Processing Plant in Barangay St. Nino, San Jose, Nueva Ecija and Poultry Processing Plant in Barangay Canitoan, Cagayan de Oro City. The identified problems of these existing machines were a) 10 percent of the chicken feathers was not removed, b) in a batch of 15 chicken, 2 pcs had broken legs; c) during the defeathering operation, workers have to pour manually 2 buckets (20-li capacity) of water, 3 d) unloading consumes about 60 seconds, and e) removing the feathers from the machine after operation was quite difficult.
 The overall dimension of chicken defeathering machine after fabrication is 1250 mm x 1160 mm x 650 mm and with a weight of 95 kg. The machine was designed to a capacity of 800 heads per hour. The performance evaluation of the machine has defeathering efficiency of 99.01% and defeathering efficacy of 95.85% at angular speed of 348 rpm. Thus, in this study, a small chicken defeathering machine was developed by improving its performance based on the problems identified above so as to make it more useful and adaptable by small scale poultry processors and poultry farmers who wish to have an added income from a dressed chicken over a live chicken.

Design, Fabrication and Performance Evaluation of Chicken De-Feathering Machine

Due to its low fat and calorie content, chicken meat is popular among non-vegetarians all over the world. The design, fabrication, and performance evaluation of a chicken de-feathering machine using locally available materials are described in this paper. The design calculations were done correctly to guarantee the right shaft diameter, as this might impact the machine's efficiency. The machine uses rubber fingers to do the actual removal of the feathers. The rubber fingers are attached to a rotating plate against a stationary plucking basin carrying protruding rubber fingers. From the analysis, a 1.0 H.P electric motor is required to drive the machine and this was used to drive the machine. Following the design and fabrication of the machine, three different types of chickens were used to test its performance. The chickens were immersed in hot water between 60 and 90 degrees Celsius and held between the 40s and 60s. The machine removed feathers without any major damage to the chickens. At each trial, the efficiency was calculated. In conclusion, the machine performed efficiently and effectively, leaving behind products that are readily marketable. Keywords: [Chicken, De-feathering, Efficiency. Fingers, Scalding, Rubber.]

Performance Assessment of Chicken De-Feathering Machine in a Small Scale Slaughtering Processors

Performance Assessment of Chicken De-Feathering Machine in a Small Scale Slaughtering Processors

DESIGN, FABRICATION AND OPTIMIZATION OF OPERATIONAL PARAMETERS OF A SMALL SCALE DE-FEATHERING MACHINE

The aim of this work is to design and fabricate a small scale de-feathering machine and investigate into the optimal operational parameters for de-feathering. The fabricated de-feathering machine has its electric motor placed by its side for easy coupling, detachability and prolonged life span of motor. It has a door by its side for easy removal of the carcass. The materials used for the fabrication of the de-feathering machine were carefully selected to ensure minimal damage to the carcass. The optimal scalding temperature of 60 o C, scalding time of 56.56 seconds, and de-feathering time of 12 seconds was found to have the highest efficiency of 96.6 %. The machine was able to achieve the desired quality. It saves time and it is of high efficiency. Keywords : DESIGN, FABRICATION AND OPTIMIZATION, DEFEATHERING MACHINE DOI: 10.7176/ISDE/12-3-04 Publication date: September 30 th 2021

Bird Feather Removal Machine: Design and Development

Poultry product have seen increasing consumers demand in recent times and processing of poultry meat is a pain staking process which is becoming extremely tasking and uneconomical given the increase in demand especially in the rural community where there is no ready access to sophisticated equipment. The Nigerian poultry sector is extremely fragmented as most poultry farmers dedicate a small setup space to satisfy small scale demand of less than 1,000 birds [1]. In commercial events, the development of a poultry de-feathering machine becomes of high priority to meet the demand for poultry products. This paper therefore advocates the implementation of the modified defeathering machine as a suitable substitute of the tradition system which is slow and tedious. This proposed system improves on the defeathering machine with the implementation of a boiling chamber for first stage scalding, and a hot spray channel directly in the plucking chamber.

Reduction Of Microbial Contamination Of Whole Broiler Chicken Carcasses During Processing

Contamination of broiler carcasses during processing with several microorganisms as salmonella, campylobacter, E. coli and staphylococcus aureus is frequently occurring. Scalding, defeathering, chilling are critical points at which cross contamination may occur during processing. Recently several interventions for carcass decontamination have been employed in order to reduce the levels of microbial hazards on poultry carcasses during processing; among which chlorine and organic acids are the most common. This study was carried out in a traditional poultry abattoir in Fayoum Governorate in order to improve the microbial quality of broiler carcasses. During 10 replicate a total of 160 carcasses were collected at 4 sampling points in the processing line (scalding, defeathering, final wash and chilling). Bacterial counts recovered from broiler carcasses rinse were lowered by 1.3, 1.3, 0.3 and 0.5 Log10 cfu ml after treatment of scalding water with 100 ppm Calcium hypochlorite in scalding. Adding peracetic acid (PAA) 50 ppm + 0.5 % acetic acid to the defeathering machine spraying system during defeathering lowered the count of coliforms and faecal coliforms significantly (P ≤ 0.05) by 1.5 and 1.6 Log10 cfu ml of carcass rinse, while it wasn't significant for E. coli and staphylococcus counts (1.2 and 0.95 Log10 cfu ml), respectively. Furthermore, significant differences in the reduction of all bacterial counts were observed in the washing stage (P ≤ 0.05) after treatment of broiler carcasses with a mixture of lactic acid 1 % + acetic acid 1 % in the final washing step. At chilling stage Na hypochlorite 50 ppm reduced the bacterial counts by 2, 2.2, 1.3 and 0.8 log10 cfu ml of carcass rinse for coliforms, faecal coliforms, Escherichia coli and staphylococcus aureus, respectively. E. coli, salmonellae, staphylococcus aureus and campylobacter spp. were reduced by different percentages. The used interventions effectively or significantly reduced microbial populations on broiler chicken carcasses during processing.

Prevalence of Campylobacter spp. in Poultry in Three Spanish Farms, A Slaughterhouse and A Further Processing Plant.

The present study was conducted to investigate the prevalence of Campylobacter spp. in a selection of poultry flocks and the corresponding broiler carcasses as well as the possible impact of contamination during slaughter and processing. Samples of the same flock at different ages in three farms (A, B and C) were taken for the determination of Campylobacter spp. The same broiler flocks were examined at different stages of one slaughterhouse and at a further processing plant. The slaughterhouse environment and processing equipment were sampled. Campylobacter spp. was not detected in 7 and 14-day-old broilers in any of the three farms studied. However, Campylobacter spp. was detected in 35 and 42-day-old broilers at two farms (Farm A and B). This pathogen was detected in both dirty and clean transport crates, in scalding water, and on the defeathering machine and the working table at the end of the working day, but not at the beginning. After defeathering, Campylobacter spp. was detected in all of the sampled carcasses. Campylobacter spp. was detected in all of the carcasses and the poultry meat portion samples from Farm C, although it was not detected at the farm level. This suggests that Campylobacter spp. infected flocks may be a source of these bacteria in the corresponding carcasses, but a cross-contamination during the transportation and slaughter process is also very important.

Contamination of chicken meat with extended-spectrum beta-lactamase producing- Klebsiella pneumoniae and Escherichia coli during scalding and defeathering of broiler carcasses

Extended-spectrum beta-lactamase- (ESBL-) producing Klebsiella (K.) pneumoniae and Escherichia (E.) coli are of critical importance in human and veterinary medicine. Animal food products, especially broiler chickens, are discussed as a possible source for the exposure of humans with antibiotic resistant bacteria. Although the occurrence and vertical transmission of ESBL-/AmpC-producing Enterobacteriaceae in the broiler production has been reported before, detailed investigations concerning the dissemination along the slaughter processing line are missing.In this study, we investigated cross-contamination with ESBL-producing Enterobacteriaceae during the processing of two different broiler flocks in one slaughterhouse. The ESBL-status during the fattening period of the flocks was determined and environmental samples from the slaughterhouse were taken before processing of the respective flocks. These isolates were compared to those found in samples from the carcasses after processing using whole genome sequencing. Phylogenetic analyses of seven ESBL-producing K. pneumoniae and 14 E. coli revealed close relationships between isolates from scalding water and the defeathering machine, respectively, which were collected before the processing of the broiler flocks, to those isolates found in samples from skin and filet of the respective flock carcasses. In conclusion, using high resolution molecular data we found evidence for the cross-contamination of carcasses with ESBL-producing Enterobacteriaceae during scalding and defeathering in the slaughterhouse.

Development and Performance Evaluation of a Chicken De-Feathering Machine for Small Scale Farmers

Development and Performance Evaluation of a Chicken De-Feathering Machine for Small Scale Farmers

Development of a Household Poultry De-Feathering Machine with Better Efficiency

Removing feathers by hand is the traditional means and method of removing feathers from poultry species. For certain reasons, removing feathers by hand was becoming obsolete since the inception of industrial age. Development of a poultry de-feathering machine is a process of producing a mechanical means of removing feathers from scalded birds. This paper focuses on development of a household poultry de-feathering machine. Meanwhile, in this paper locally available materials were used for the development of the devise. Design calculations were done appropriately to ensure correct shaft diameter as this could affect the efficiency of the machine. The machine consists of rubber pluckers which do the actual picking of the feathers. The rubber pluckers are attached to a rotating plate against a stationary plucking basin carrying protruding rubber pluckers. Test was carried out on the machine with three spent layer chickens. The chickens were soaked inside hot water at about 70°c and held for about 45-60s. The machine removed feathers without any major damage to the chickens. The efficiency at each trial was calculated and average efficiency was calculated to be approximately 95%. In conclusion, the machine performed efficiently and effectively, leaving behind products that could meet market standard.

The Contribution of Airborne Contamination to Campylobacter Counts on Defeathered Broiler Carcasses

The enteric pathogen Campylobacter can be carried into poultry processing facilities on and within live birds. Numbers of Campylobacter recovered from carcasses decrease after scalding but increase during feather removal. Mechanical feather picking causes mist as well as particles of dust, feathers, feces, and other matter to become airborne around the machine. This study was conducted to determine if Campylobacter associated with broilers during defeathering can become airborne and contaminate other carcasses in or around a commercial defeathering machine. Carcasses with low numbers of Campylobacter were hung near an operating commercial feather picker where they were exposed to airborne contaminants for 1min. Low numbers of Campylobacter were detected in the air near the picker. However, microbiological culture of carcasses after exposure to airborne contamination in the picker room revealed that they had no more Campylobacter than unexposed carcasses. These data suggest that airborne contamination does not contribute to the high numbers of Campylobacter routinely found on defeathered carcasses.

Microbial cross-contamination by airborne dispersion and contagion during defeathering of poultry

1. A readily identifiable strain of Escherichia coli K12 was used as a 'marker' organism to determine the sources, routes and patterns of microbial cross-contamination during mechanical defeathering of broiler chicken carcases. 2. Inoculation of scald water with the marker organism led to a relatively even pattern of carcase contamination during subsequent defeathering. Microbial cross-contamination was greater by this route of inoculation than by either surface inoculation of a 'seeder' carcase or oral inoculation of a live bird one day before slaughter. 3. Dispersal of the marker organism was strongly influenced by the mechanical action of the defeathering machines. Forward transmission of the marker occurred by aerosol or large airborne droplets and particulates such as feathers. Moving carcases through the defeathering machines when these were non-operational clearly reduced backward transmission of the marker. 4. Although microbial dispersal was unaffected by increasing the spacing between individual carcases or installing a water curtain at the entry and exit of the defeathering machines, shielding of carcases with aluminium baffles reduced counts of the marker organism from contaminated carcases by > 90%. 5. The results imply that microbial cross-contamination of broiler chicken carcases during defeathering occurs mainly via the airborne route, which could be contained by physical means.

Bacterial Populations Associated with the Dirty Area of a South African Poultry Abattoir

Bacterial populations associated with three sample types from the neck region of poultry carcasses in the dirty area of an abattoir were characterized. Sample types before and after scalding were skin only, feathers only, and a skin and feather combination. The neck skin of carcasses after the defeathering processing stage was also sampled. Bacterial populations associated with water from the scald tank, rubber fingers at the exit of the defeathering machine, and air in the dirty area were also characterized. Bacterial colonies (751) were randomly isolated from yeast extract-supplemented tryptone soya agar plates exhibiting 30 to 300 colonies. Micrococcus spp. were isolated in the highest proportion from pre- and postscalded carcass samples (63.5 to 86.1% of isolates), regardless of the sample type. Conversely, Enterobacteriaceae (40.3%), Acinetobacter (19.4%), and Aeromonas/Vibrio (12.5%) species predominated on neck skin samples taken from mechanically defeathered carcasses. Isolates from the rubber fingere were, however, predominantly Micrococcus spp. (94.4%). Bacterial groups isolated in the highest proportion from scald tank water samples were Micrococcus spp. (38.3%), species of Enterobacteriaceae (29.1%), and lactic acid bacteria (17.0%). Corynebacterium spp., species of Enterobacteriaceae, and Micrococcus spp. were dominant on air settle plates.

Bacterial Populations of Different Sample Types from Carcasses in the Dirty Area of a South African Poultry Abattoir

Bacterial populations associated with three different sample types from carcasses in the dirty area of a South African poultry abattoir were compared. The three sample types from carcasses before and after scalding included neck skin only, feathers only, and a neck skin and feather combination. The neck skin of carcasses after defeathering was also sampled. Aerobic plate counts, Enterobacteriaceae counts, and Pseudomonas spp. counts were performed on all sample types, as well as on water, air, and equipment samples from the same area. The prevalence of potential pathogens was also investigated. Neck skins sampled before and after scalding consistently exhibited the lowest counts for all bacterial types, and feathers the highest. In most cases, the bacterial numbers of the neck skin samples from pre- and postscalded carcasses were significantly lower (P < 0.05) than those of feather samples and neck skin and feather combination samples. Scalding of carcasses resulted in a consistent decrease of bacterial populations, reflected by all three sample types. Neck skins sampled after defeathering, however, exhibited increased bacterial numbers compared to neck skins sampled postscalding, implicating the rubber fingers of the defeathering machine as contamination sources. These equipment surfaces exhibited aerobic plate counts as high as 7.7 log CFU/cm2. Potential pathogens were isolated from product as well as selected environmental samples. The prevalence of the potential pathogens was found to vary depending on the sample type.

Identification of a starting point of breast skin tears during chicken plucking

A site (STP) was identified on the skin of the chicken, during defeathering in the slaughter house, at which about 90% of breast skin tears started. This site is on the ventral side of the pectoral tract area. There was no difference in location of this site with respect to different commercial lines, sexes, flocks, or time of the day. In order to demonstrate the importance of a small skin tear to ultimate damage, defeathered chickens with a minor tear at a particular site and undamaged defeathered chickens were passed through the defeathering machine a second time. Thirty-six percent of the STP chickens were torn further, but only a small percentage (about 4%) of the undamaged chickens were harmed.