Poultry Processing Industry Research Articles

A estruturação da rede de empresas processadoras de aves no Estado de Santa Catarina: governança contratual e dependência de recursos

O objetivo deste artigo é verificar a formação distribuição de recursos dinâmicos de poder das empresas processadoras avícolas do estado de Santa Catarina. O desenvolvimento do sistema de contratos de integração na avicultura catarinense teve influencia de diversos fatores: características históricas (experiência com a suinocultura), regional (proximidade com a cultura da soja), participação política, ações individuais e coletivas (associações) dos atores, recursos dinâmicos de poder (constitucionais, tecnológicos, financeiros, políticos, organizacionais e jurídicos). Nesse contexto, foi possível concluir a avicultura sulista teve trajetória de dependência (path dependence) bem distinta, o que conduziu à estruturação do sistema de contratos de forma mais eficiente do quem outras regiões do país.

CHARACTERIZING WHOLESOME AND UNWHOLESOME CHICKENS BY CIELUV COLOR DIFFERENCE

An automated poultry carcass inspection system will help the poultry processing industry to provide better chickenproducts for the consumer while minimizing potential economic losses. The objective of this research was to investigate thepotential of a color-based sensing technique suitable for rapid automated inspection for wholesomeness of chickens in thevisible region. Spectra, in the range of 400 to 867 nm, of veterinarian-selected carcasses, 400 wholesome and332 unwholesome, were collected from a high-speed kill line using a visible/near-infrared spectrophotometer system.CIELUV color differences characterizing wholesome and unwholesome chicken samples were calculated as a simple distanceformula and used to classify individual samples. Results showed that the greatest color differences occurred for wavebandcombinations at (508 nm, 426 nm), (560 nm, 426 nm), and (640 nm, 420 nm). Full-spectrum classification achieved accuraciesof 85%, 86%, 84%, and 82% for wholesome validation samples, wholesome testing samples, unwholesome validationsamples, and unwholesome testing samples, respectively. Using the (560 nm, 426 nm) waveband combination, classificationaccuracies of 91%, 92%, 90%, and 90% were achieved for wholesome validation samples, wholesome testing samples,unwholesome validation samples, and unwholesome testing samples, respectively. The potential of using CIELUV colordifferences to differentiate between wholesome and unwholesome chickens was demonstrated, and the straightforwardcalculation involved suggest that the method is suitable for rapid automated online sorting of chicken carcasses.

Recycling of Keratin-containing Materials (Chicken Feather) Through Genetically Engineered Bacteria

Chicken feather is mainly keratin which is not normally degraded by common proteolytic enzymes. It is generated in large quantities as a by-product of poultry processing industry and little is known about its recycling. We reported the biodegradation of chicken feather waste (CFW) by a recombinant Bacillus subtilis strain harboring a multicopy alkaline protease (aprE) gene which acted as a keratinase. In present work, degradation of CFW was greatly enhanced by optimizing several factors. Pretreatment of CFW with NaOH or two times autoclaving enhanced the process. Cultures supplemented, separately, with 0.1% yeast extract or 0.5% corn oil enhanced the degradation of CFW. Biodegradation was optimized when the cultures contained 2% (w/v) CFW, 5% inoculum size, and incubated at 45°C for 3–4 days. Biodegradation was evaluated by monitoring soluble proteins and NH2-free amino groups that were obtained as a result of the enzymatic hydrolysis of feather. Biodegradation of feather waste using these recombinant cells represents an alternative way to improve the nutritional value of feather. Moreover, the release of soluble proteins and amino acids from feather as well as the secreted keratinase enzyme would promote several industries based on feather waste.

Production yield analysis in the poultry processing industry

The paper outlines a case study where the PYA-method (production yield analysis) was implemented at a poultry-slaughtering line, processing 9000 broiler chicks per hour. It was shown that the average live weight of a flock of broilers could be used to predict the maximum production yield of the parts (fillet, legs, wings, etc.). For all parts a strong linear relationship for the weight of the parts with the average live weight (LW) was found. Significant differences ( P⩽0.05) between the strains Ross 308 and 508 were observed. Ross 308 showed significant higher yields for feet, guts and lungs, heart (LW < 1626.2 g), skinned gizzard, neck without skin, tail (LW > 1907.4 g), skeleton frame of the breast, saddle and legs. Ross 508 showed significant higher yields for chilled carcass, heart (LW > 1626.2 g), tail (LW < 1907.4 g), breast, fillet and upper back. The Yield Indexes that were calculated for the various parts varied between 0.5 and 1.0 and showed remarkable potentials for yield improvement. Yield improvements were realised by many actions like: good housekeeping, training and instructing of employees, fine-tuning of equipment and replacement of out dated machinery or parts of it.

Removal of Selenium and Arsenic by Animal Biopolymers

The animal biopolymers prepared from hen eggshell membrane and broiler chicken feathers, which are byproducts of the poultry-processing industry, were evaluated for the removal of the oxyanions selenium [Se(IV) and Se(VI)] and arsenic [As(III) and As(V)] from aqueous solutions. The biopolymers were found to be effective at removing Se(VI) from solution. Optimal Se(IV) and Se(VI) removal was achieved at pH 2.5-3.5. At an initial Se concentration of 100 mg/L (1.3 mM), the eggshell membrane removed approx 90% Se(VI) from the solution. Arsenic was removed less effectively than Se, but the chemical modification of biopolymer carboxyl groups dramatically enhanced the As(V) sorption capacity. Se(VI) and As(V) sorption isotherms were developed at optimal conditions and sorption equilibrium data fitted the Langmuir isotherm model. The maximum uptakes by the Langmuir model were about 37.0 mg/g and 20.7 mg/g of Se(VI) and 24.2 mg/g and 21.7 mg/g of As(V) for eggshell membrane and chicken feathers, respectively.

Utilization of Turkey Feather Fibers in Nonwoven Erosion Control Fabrics

Currently, between two and four billion pounds of feathers are produced annually by the poultry processing industry (1). These feathers present a disposal problem, and are usually converted to animal feed. A method of effectively stripping the feather fibers from the quill without damaging the fibers has been patented, and as a result research is being conducted to determine uses for these fibers (4). Current research has focused on creating latex bonded fabrics containing turkey feather fibers for utilization as erosion control fabrics. These fabrics have been compared with currently available erosion control fabrics to determine their suitability for this particular purpose. The turkey fiber fabrics performed similarly to the commercially available erosion control fabrics tested in terms of light and water transmittance. None of the fabrics significantly affected the pH, nitrogen or phosphorus content of the soil even though the turkey fabrics had fully decomposed by the conclusion of the experiment. The turkey fabrics increased soil moisture content and decreased soil compaction, which are critical properties for successful ecological restoration of habitats. One significant drawback of the turkey fabrics was difficulty in handling and installation on the site compared to the two commercial erosion control fabrics tested.

Prediction of Fat Content in Poultry Meat by Near-Infrared Transmission Analysis

The meat industry routinely determines fat content of meat for quality monitoring and processed product formulation. Meat, as a raw material, is extremely variable and may range from 1 to 65% fat. Fat analysis on a batch-by-batch basis is essential. The reference methods for fat are typically time consuming and generate hazardous waste [1]. In the past 10 yr, near-infrared reflectance (NIR) and transmittance (NIT) spectroscopy have gained widespread use for analyses of quality constituents in many materials. Near-infrared spectroscopy relies on a reference method for calibration and instrument standardization. However, it is often preferred to reference methods because it is rapid, accurate, and cost effective; it does not require skilled operators; and it does not generate hazardous waste. The use of NIT for the prediction of fat in boned raw poultry breast muscle, trimmings, and raw finished product (chicken nuggets) was investigated in this study. We used a database supplied by the NIT instrument manufacturer and samples collected from a local processing plant to develop fat calibration models with an error of 0.70 and 0.33% fat, respectively. Fat calibration models were validated with local processor samples. The standard error of performance was 0.84 and 0.38% fat for the instrument manufacturer and local processor calibration, respectively. Typical within-product standard errors for other rapidmethods are 0.9 and 1.6%for Banco andUnivex rendering, respectively [2]. Badcock fat has been rejected as an official method due to loss of accuracy for samples greater than 27% fat and high bias for samples less than 27% fat [2]. Standard errors for Official AOAC Soxhlet type methods have ranged from 0.41 to 1.14% for fat [1]. USDA performance criteria for repeatability require standard errors of less than 0.63 for fat [1]. This study supports that NIT can be a useful tool in the poultry processing industry for fat analysis in quality monitoring and processed product formulation.

Isolation and characterization of a feather-degrading bacterium from the poultry processing industry

A Flavobacterium sp. producing a high keratinolytic activity was isolated from a poultry industry after growth on selective feather meal agar. This bacterium grew on feather meal broth, producing keratinase, and was also capable of complete degradation of raw feathers. The proteolytic activity was assessed in the presence of specific protease inhibitors. The crude enzyme showed mainly metalloprotease character. This novel isolate would have potential biotechnological use in processes involving keratin hydrolysis.

Isolation and characterization of a feather-degrading bacterium from the poultry processing industry.

A Flavobacterium sp. producing a high keratinolytic activity was isolated from a poultry industry after growth on selective feather meal agar. This bacterium grew on feather meal broth, producing keratinase, and was also capable of complete degradation of raw feathers. The proteolytic activity was assessed in the presence of specific protease inhibitors. The crude enzyme showed mainly metalloprotease character. This novel isolate would have potential biotechnological use in processes involving keratin hydrolysis.

Volatiles from roasted byproducts of the poultry-processing industry.

Volatiles of roasted chicken breast muscle and byproducts, such as backbones, breastbones, spent bones, and skin, were investigated. Total volatile concentrations ranged from 2030 ppb in the roasted backbones to 4049 ppb in the roasted skin. The major classes of volatile compounds detected in roasted samples were aldehydes (648-1532 ppb) and alcohols (336-1006 ppb). Nitrogen- and/or sulfur-containing compounds were also detected in appreciable quantities (161-706 ppb) in all samples. For all samples, hexanal and 2-methyl-2-buten-1-ol were dominant among the aldehydes and alcohols, respectively. Among the nitrogen- and sulfur-containing compounds, Maillard reaction products, such as tetrahydropyridazines, piperidines, and thiazoles, were the major contributors to the total volatile content in all samples. The composition of volatiles observed in roasted byproducts was markedly different from that of the roasted breast muscle. Therefore, the blending of the byproducts in appropriate proportions or blending of volatile flavor extracts from different byproducts may be necessary to obtain an aroma that mimics roasted chicken aroma.

Succeeding in the post‐BSE UK meat, poultry and cheese processing and packaging industries

This article looks at how certain companies within the UK meat, poultry and cheese packaging and processing industries have achieved success within the new market environment created in the aftermath of the BSE crisis. The study utilises a postal questionnaire sent to 50 companies in these industries and identified three sets of industry key success factors or strategies: focus on the customer, focus on value added, focus on pursuing improvements. The strategies identified within those areas can provide such organisations with basic policies which can improve the probability of emerging as successful in a changing environment.

U.S. Poultry Processing Employment and Hourly Earnings

Various governmental information sources show sizeable differences in total employment in the poultry processing industry. Bureau of Labor Statistics employment estimates for some years are more than 20% larger than corresponding values reported by the Census of Manufacturers/Annual Survey of Manufacturers or County Business Patterns. The publicly available sources of information give more consistent reports on average hourly earning of production workers in the poultry processing industry than on total employment in the industry. Although nominal hourly earnings have increased over time, deflating these figures with different measures of relative price changes can result in varying trends in real hourly earnings. Deflating earnings by the Consumer Price Index produces a negative trend in hourly earnings between the late 1970s and early 1990s. Deflating by the price index for nondurable component of personal expenditure component of GNP, however, result in a generally upward, but not continuous, trend in real hourly earnings after 1974. Such variations among sources of information and methods of analysis account for confusion and differences of opinion about total employment and hourly earnings in the poultry processing industry.

Exposure to air contaminants in chicken catching.

A cross-sectional study of chicken catchers was carried out by personal sampling of air contaminants. The catchers used either the drawer method (DM) or truck method (TM) for loading chickens into cages. DM catchers were exposed to higher concentrations of hazardous substances than TM catchers, except for ammonia. In terms of geometric means total dust concentrations were 11.3 mg/m3 (DM catchers) and 8.1 mg/m3 (TM catchers). Full-shift dust exposure exceeded the Danish occupational exposure limit (OEL) of 3 mg/m3 for organic dust by at least a factor of 2. From paired personal sampling data the concentration of respirable dust ranged from 18% to 28% of the total dust concentration. The average exposure level to bacterial endotoxin in total dust at 82 ng/m3 for DM catchers and 42 ng/m3 for TM catchers exceeded a limit of 10 ng/m3 recommended for poultry processing industry workers in the United States. Endotoxin content of airborne dust averaged 6.5 +/- 4.9 ng/mg. Exposure to microorganisms was determined by microscopy (total count) and by culturing (viable count). The geometric means for total count (microorganisms/m3) were 7.0 x 10(8) (DM catchers) and 4.9 x 10(8) (TM catchers) and for viable count 3.2 x 10(7) cfu/m3 (DM catchers) and 1.4 x 10(7) cfu/m3 (TM catchers). The ratio of microorganisms counted by microscopy to levels of viable microorganisms ranged from 5 to 200, implying a strong underestimation of exposure levels from viable counts alone. It was concluded that Danish chicken catchers were exposed beyond recommended limits for the air contaminants evaluated.(ABSTRACT TRUNCATED AT 250 WORDS)

Feather meal, a semi-slow-release nitrogen fertilizer for organic farming

Plant nutrition in organic farming is based entirely on decomposition of organic materials, and release of excess N superfluous to the microbial population. Feather meal (FM), a by-product of the poultry processing industry, which contains 15% N as non-soluble keratin, is a potential organic N fertilizer. The objective of this study was to determine the rate of N mineralization and changes in microbial activity following the application of FM to soil. Soils were incubated with FM for 8 weeks at 30°C and optimal water content, and analyzed periodically for inorganic N, rate of CO2 evolution, counts of microbial populations, and activity of dehydrogenase and protease. Approximately 45, 55 and 65% of fertilizer N were released after 1, 2, and 8 weeks, respectively. Total number of bacteria increased due to the addition of FM after only 1 d, with a second pulse obtained at 14 d. Dehydrogenase activity followed a similar response cycling. Cellulose hydrolyzing bacteria and proteolitic bacteria increased later, between 5 and 21 d, probably due to secondary microbial decay products. Microbial biomass N at 5 to 7 d accounted for 10 to 14% of total FM-N, therefore the slow release of N from FM was due in part to its resistance to decomposition and in part to microbial biomass build-up and secondary decomposition.

Development of a Constant Current Water Bath Stunner for Poultry Processing

Problems with conventional water bath stunners have been identified through observation in commercial processing plants and experiment in the laboratory. Due to differences in the electrical resistance of the individual birds there is little control over the stunning current and hence the effectiveness of stunning. To illustrate this problem, the use of set voltage waterbath stunners in the poultry processing industry is described. Their performance in relation to existing UK legislation and proposed European standards for animal welfare is discussed.A prototype poultry stunner has been developed which controls the current delivered to individual birds. The stunning current has a 50 Hz sinusoidal wave form and the root mean square (r.m.s.) value is adjustable between 50 and 200 mA. The machine is capable of operating at typical commercial processing speeds of 6000 birds per hour. Experiments using dummy birds, built with electrical properties to represent a live chicken, show that the system can deliver and maintain a preset, constant current to each individual bird provided there is no significant current pathway between adjacent birds. A constant current stunning system will control the current flow through individual birds at an optimal level which will ensure an effective stun and at the same time minimize the carcass quality problems produced by high currents.

Nunc Dimittis

George A. Schuler, Professor of Food Science, University of Georgia, died March 3, 1993 in Athens, GA. Schuler held degrees from Pennsylvania State University, University of Tennessee, and Virginia Polytechnic Institute and State University. As an Extension Specialist in the University of Georgia Cooperative Extension Service, he worked with the poultry industry for 21 years. He was most noted for the sanitation programs he initiated long before Hazard Analysis Critical Control Point became a buzzword in the food industry. Schuler traveled extensively around the world teaching sanitation principles and production practices needed to ensure economic viability of the poultry processing industry. He was a professional member of the Institute of Food Technologists and past chairman of the Dixie Section. Schuler served on several committees of the Poultry Science Association, World Poultry Science Association, Georgia Poultry Federation, and Southeastern Poultry and Egg Association. Friends and colleagues will miss his pleasant company.

Poultry processing

A consumer expects poultry on sale in shops and supermarkets to be of high quality, safe to eat and, increasingly nowadays, to have been humanely produced. These criteria can only be met if the birds are well treated when alive and their carcases hygienically processed after they are dead. The responsibility for the birds’ welfare while growing lies mainly in the hands of the farmer; once they have left the farm it largely falls upon the poultry processing industry.

Assessing the impact of the Canada—US trade agreement on food processing in Canada: An analytical framework and results for poultry, dairy, and tomatoes

This article assesses the impact of the Canada—US Trade Agreement (CUSTA) on food processors in Canada. It examines the interaction between Canada's agricultural marketing boards and changes to domestic and border regulation resulting from CUSTA on processors in the poultry, dairy, and tomato processing industries. The results vary by the processed product but suggest that the chicken industry needs to make the biggest adjustment, while the tomato industry is best positioned to make the changes required to become competitive.

Organic Dust, Endotoxin, and Ammonia Exposures in the North Carolina Poultry Processing Industry

Abstract The growth of the poultry processing industry was possible because of veterinary preventive medicine techniques and improvements in breeding, feed conversion, housing, and marketing practices. Increased production of broilers has caused an increase in the amount of airborne contaminants to which poultry processing workers (growers, catchers, and hangers) are exposed. The purposes of this research were to evaluate the exposures experienced by poultry processing workers in North Carolina and to recommend control measures for reducing exposures below levels considered to be safe. Exposure estimates were compared to 8-hour time-weighted average (TWA) limits of 10 mg/m3 for total dust, 5 mg/m3 for respirable dust, 10 ng/m3 for bacterial endotoxin, and 25 ppm for ammonia with a STEL of 35 ppm. Personal sampling at 22 North Carolina poultry farms involving 26 growers produced geometric mean 8-hour TWA concentrations of 11.6 mg/m3 for inhalable dust, 0.60 mg/m3 for respirable dust, 100 ng/m3 for inhalabl...

Comparison of the limulus amebocyte lysate test and gas chromatography-mass spectrometry for measuring lipopolysaccharides (endotoxins) in airborne dust from poultry-processing industries

The lipopolysaccharide (endotoxin) content in airborne dust samples from three different poultry slaughterhouses was determined with both the chromogenic Limulus amebocyte lysate assay and gas chromatography-mass spectrometry analysis of lipopolysaccharide-derived 3-hydroxy fatty acids. Gram-negative cell walls were also measured by using two-dimensional gas chromatography/electron-capture analysis of diaminopimelic acid originating from the peptidoglycan. The correlation between the results of the Limulus assay and those of gas chromatography-mass spectrometry for determination of the lipopolysaccharide content in the dust samples was poor, whereas a good correlation was obtained between lipopolysaccharide and diaminopimelic acid concentrations with the gas chromatographic methods. The results suggest that it is predominantly cell-wall-dissociated lipopolysaccharides that are measured with the Limulus assay, whereas the gas chromatographic methods allow determination of total concentrations of lipopolysaccharide, including Limulus-inactive lipopolysaccharide, gram-negative cells, and cellular debris.