Poultry Processing Research Articles

Alternative slaughter procedures: on-farm slaughter and transport system for broilers

This paper focuses on "alternative methods for initial broiler processing" and exploration of alternative processing including slaughter at the farm immediately after catching. On-farm slaughter and transport (FSaT) is envisioned as a mobile unit that stuns, slaughters, and shackles the broiler carcasses at the farm. A separate trailer-unit then transports the shackled broiler carcasses to the processing plant. Once at the processing plant carcasses are mechanically transferred into plant shackle lines and moved into processing. The hypothesis is that the FSaT approach will dramatically improve overall bird welfare and well-being by reducing live handling and eliminating live transport from the farm to the processing plant. In addition, ancillary impacts could include: improving yield efficiencies by eliminating dead on arrivals, potentially reducing water and energy consumption, reducing labor requirements at the processing plant with the elimination of live rehang, and offering an economically sustainable alternative. The FSaT approach represents a radical change from traditional processing, and its effects on poultry processing need to be evaluated. This paper presents results of experiments conducted at a commercial poultry processor to evaluate feather picking efficiency, carcass bacteriological loading, and meat quality for delayed processed carcasses.

The Southern Model Revisited: The Intersection of Race, Ethnicity, Immigration, and Health and Safety in Poultry Processing

This research combines a sociology of agrifood conceptual framework with a commodity systems analysis methodology to investigate the nexus of race, ethnicity, immigration, and health and safety in the US poultry processing industry. The poultry industry was the first agricultural sector to industrialize. Through vertical and horizontal integration, the industry is dominated by a few powerful firms. The industry has been criticized for multiple ethical failures regarding contract growers, processing plant workers, and communities. Meat and poultry processing is one of the most dangerous manufacturing jobs in the United States. Poultry processing is especially reliant on a non-union, minority, and immigrant labor force. This “Southern Model” is the preferred model of agrifood globalization. The COVID pandemic brought renewed attention to precarious work in poultry processing and exposed the lack of resilience in the agrifood system in general, and the poultry industry in particular.

Aerotolerance and Multi-Locus Sequence Typing of Campylobacter jejuni Isolated from Commercial Broiler Processing Plants.

Campylobacter jejuni is one of the leading causes of acute diarrhea in the United States. Despite being a microaerophilic pathogen, C. jejuni continues to endure within the domain of food production, especially in poultry processing. Recent research on aerotolerance indicates that close monitoring of this pathogen is necessary. A total of 40 C. jejuni isolates previously obtained from commercial broiler processing plants were analyzed for aerotolerance and genetic diversity. In addition, the effect of aerotolerance and storage time (days) on the survival of C. jejuni on broiler drumsticks at refrigeration (4 °C) and freezing conditions (-20 °C) was also evaluated. Out of 40 isolates, 25 (62.5%) were aero-sensitive (AS), 10 (25%) were intermediately aerotolerant (IAT), and 5 (12.5%) were hyper aerotolerant (HAT). The isolates belonged to four clonal complexes (CCs) and six sequence types, with the majority of isolates assigned to the CC-353 clonal complex. C. jejuni counts were reduced by 0.40 log CFU/g after 7 days at 4 °C and by 1.50 log CFU/g after 14 days at -20 °C, respectively, irrespective of aerotolerance (p < 0.001). At both refrigeration (p < 0.013) and freezing (p < 0.001), HAT showed greater reductions as compared to AS and IAT. These findings suggest that both refrigeration and freezing reduce C. jejuni counts.

Research on automatic classification and detection of chicken parts based on deep learning algorithm.

Accurate classification and identification of chicken parts are critical to improve the productivity and processing speed in poultry processing plants. However, the overlapping of chicken parts has an impact on the effectiveness of the identification process. To solve this issue, this study proposed a real-time classification and detection method for chicken parts, utilizing YOLOV4 deep learning. The method can identify segmented chicken parts on the assembly line in real time and accurately, thus improving the efficiency of poultry processing. First, 600 images containing multiple chicken part samples were collected to build a chicken part dataset after using the image broadening technique, and then the dataset was divided according to the 6:2:2 division principle, with 1200 images as the training set, 400 images as the test set, and 400 images as the validation set. Second, we utilized the single-stage target detector YOLO to predict and calculate the chicken part images, obtaining the categories and positions of the chicken leg, chicken wing, and chicken breast in the image. This allowed us to achieve real-time classification and detection of chicken parts. This approach enabled real-time and efficient classification and detection of chicken parts. Finally, the mean average precision (mAP) and the processing time per image were utilized as key metrics to evaluate the effectiveness of the model. In addition, four other target detection algorithms were introduced for comparison with YOLOV4-CSPDarknet53 in this study, which include YOLOV3-Darknet53, YOLOV3-MobileNetv3, SSD-MobileNetv3, and SSD-VGG16. A comprehensive comparison test was conducted to assess the classification and detection performance of these models for chicken parts. Finally, for the chicken part dataset, the mAP of the YOLOV4-CSPDarknet53 model was 98.86% on a single image with an inference speed of 22.2 ms, which was higher than the other four models of YOLOV3-Darknet53, YOLOV3-MobileNetv3, SSD-MobileNetv3, and SSD-VGG16 mAP by 3.27%, 3.78%, 6.91%, and 6.13%, respectively. The average detection time was reduced by 13, 1.9, 6.2, and 20.3 ms, respectively. In summary, the chicken part classification and detection method proposed in this study offers numerous benefits, including the ability to detect multiple chicken parts simultaneously, as well as delivering high levels of accuracy and speed. Furthermore, this approach effectively addresses the issue of accurately identifying individual chicken parts in the presence of occlusion, thereby reducing waste on the assembly line. PRACTICAL APPLICATION: The aim of this study is to offer visual technical assistance in minimizing wastage and resource depletion during the sorting and cutting of chicken parts in poultry production and processing facilities. Furthermore, considering the diverse demands and preferences regarding chicken parts, this research can facilitate product processing that caters specifically to consumer preferences.

Comparison of peroxyacetic acid and acidified sodium chlorite at reducing natural microbial contamination on chicken meat pieces

The spin-chill process at poultry processing plants involves the immersion of chicken carcasses in cold water (<5°C) often containing sodium hypochlorite which significantly contributes to the reduction of bacterial loads. Cutting carcasses into pieces, however, has been linked with increases in Campylobacter and Salmonella counts. Here, the efficacy of PAA and ASC on reducing bacteria on skin-on, bone-in thigh cuts was investigated. Three concentrations of ASC (60, 112, and 225 ppm) and PAA (50, 75, 100 ppm) were used. Thighs were dipped into sanitizer and tested for total viable bacterial counts, Campylobacter load, and prevalence of Salmonella. The efficacy of PAA and ASC was also compared with chlorine (8 ppm). All sanitizers exhibited a greater log reduction compared with water. PAA at both 75 and 100 ppm resulted in significantly higher log reductions compared with the water only. PAA at 100 ppm and 225 ppm ASC were the most effective at reducing Campylobacter. All wash treatments reduced the proportion of Salmonella positive samples, but the greatest reduction was observed for 225 ppm ASC. Both concentrations of ASC resulted in a greater reduction in total viable counts compared with chlorine.

Muscle fiber characteristics and expression level of Troponin T3, Toll-like receptor 2, and Toll-like receptor 4 genes in chicken meat with white striping.

The poultry industry faces an emerging muscular defect in chicken meat called white striping (WS). The biological processes associated with WS myopathy are immune system activation, angiogenesis, hypoxia, cell death, and striated muscle contraction. We examined the Troponin T3 (TNNT3), Toll-like receptor 2 (TLR2), and Toll-like receptor 4 (TLR4) genes based on their functions related to muscle contraction and the innate immune system. This study aimed to determine the muscle fiber characteristics (MFCs) and expression level of TNNT3, TLR2, and TLR4 genes in white striping chicken meat (WSCM). A total of 428 breast samples were randomly collected from a commercial poultry processing plant. The samples were classified into four levels: 0 (normal), 1 (moderate WS), 2 (severe WS), and 3 (extreme WS). Five samples per group were selected to evaluate MFCs, including total number of muscle fibers, muscle fiber diameter, cross-sectional area, endomysium thickness, and perimysium thickness. Five samples per group were selected for ribonucleic acid (RNA) isolation to evaluate the messenger RNA (mRNA) expression levels of TNNT3, TLR2, and TLR4 genes related to WS. Statistical analysis revealed that the total number of fibers, endomysium thickness, and perimysium thickness significantly differed between groups (p < 0.05). Muscle fiber diameter and cross-sectional area did not significantly differ (p > 0.05). The expression of the TNNT3 gene did not significantly differ among groups (p > 0.05). Toll-like receptor 2 and TLR4 mRNA expression significantly differed among groups (p < 0.05). These detailed MFCs will provide baseline information to observe WS in chicken meat. Toll-like receptor 2 and TLR4 genes may play a role in the occurrence of WS in chicken meat through non-specific immune reactions.

Impact of water as raw material on material circularity - A case study from the Hungarian food sector

Measuring circularity is necessary to prove the feasibility of transforming linear technologies into circular ones. However, most of the circular economic researches consider water only as a medium. Food industry processes are excellent examples of systems that are hard to break free from linearity, albeit not impossible. This paper explores solutions to include water in circularity calculations using a Hungarian poultry processing plant as a case study. Two circular economic indicators, the questionnaire-type Circular Economy Indicator Prototype (CEIP) and the product-centric Material Circularity Indicator (MCI and MCI’) and the Water Footprint were examined in detail and modified to fit the needs of assessing circularity with water included as raw material. The calculations were supported by Life Cycle Assessment (LCA). The impact on circularity and the environment were quantified by considering different reuse scenarios. As the results of CEIP show, including water reuse in the technology or recycling for irrigation could increase the indicator values from low to medium-high level of circularity. However, the level of improvement highly depends on the amount of water used. LCA highlighted the significant environmental effects of packaging (<2% of product mass) and the relative benefits of recycling and reuse. The MCI’ values (including water as raw material) increased from 0.171 to 0.848 when water demand was reduced by 50% and 100% reused within the processes. This led to a reduction of 76% in the environmental effect. On the other hand, Water Footprint analysis showed that 99% of the water is incorporated in the product itself; therefore, technological water consumption should be treated separately from broiler breeding. The results show that a fairly linear process can be directed towards circularity. However, environmental benefits are not guaranteed with higher circularity points, and recycling may lead to unexpected results.

Mapping of dressed and processed poultry products in Bangladesh: Identifying the food safety risks for policy intervention

Bangladesh’s commercial poultry production is growing rapidly, including the commercial processing of poultry. This expansion of poultry processing plants is fueled by the belief that this sub-sector provides safer food and has less food-borne disease risks compared to traditional live bird markets (LBMs). The purpose of this study is to describe Bangladesh’s dressed and processed poultry production and distribution network (PDN), identify what and where quality control occurs, and suggest where improvements could be made. Engaging with PDN for dressed and processed poultry, we used in-depth interviews with key informants to identify the stakeholders involved and their connections with other poultry PDNs. In addition, we mapped out the supply and distribution of dressed and processed poultry and quality control processes occurring throughout the network. We argue that dressed and processed poultry PDNs are closely connected with traditional PDNs such as LBMs, with multiple crossover points between them. Also, there is a lack of consistency in quality control testing and a lack of meat traceability. Consequently, perceptions of dressed and processed poultry being safer than birds from LBMs needs to be treated with caution. Otherwise, unsubstantiated consumer confidence in dressed poultry may inadvertently increase the risk of food-borne diseases from these products.

Mixed Messages and COVID-19 Prevention: Why Information Is Not Always Enough to Protect Meat Processing Workers

The objective of this project was to investigate U.S. meat and poultry processing workers' knowledge of COVID-19, perceived ability to protect themselves from infection, and perspectives on COVID-19 vaccines to inform COVID-19 prevention efforts within this linguistically, racially, and ethnically diverse workforce. Qualitative semi-structured in-depth interviews were conducted with Mexican, Central American, Congolese refugee, and Black or African American meat/poultry processing workers from Mississippi, Minnesota, Virginia, and Kentucky (N=40). Data were collected from December 5, 2020, to January 28, 2021. Interview audio was transcribed, and rapid qualitative data analysis was used to analyze transcripts. Most participants expressed receiving mixed messages about COVID-19 protection measures: they were told how to protect themselves (n=38), but workplace policies (such as lack of paid sick leave) often undermined their efforts. Participants who were asked about COVID-19 vaccines (n=31) were aware there were one or more vaccines available to protect them from COVID-19; one-third were eager to get vaccinated. Community-based efforts may consider supplementing large scale unified information campaigns in order to prevent mixed messages, address worker needs to accurately gauge the threat of illness to their families and communities and empower them to prevent infection.

Meat Species Identification in Chicken Blood Meal using Polymerase Chain Reaction Technique

A study was conducted to identify the species of chicken in high heat processed chicken secondary by-product comprising of poultry blood meal. A total of 30 samples of poultry blood meal were collected from different poultry processing plants in Tamil Nadu. Species specific polymerase chain reaction was employed to validate the meat species identification in heat processed secondary poultry by-products. Custom designed primer sequences of mitochondrial cyt b gene were utilised for the present study. The results revealed successful amplification of chicken species at 227 base pairs in samples of all the blood meal samples. Thus, it was concluded that species specific polymerase chain reaction technique can be effectively used in the screening of chicken meat species in different heat processed secondary by-products for quick and reliable results.

High-Intensity Ultrasonication as an Innovative Approach for the Softening of Wooden Breast Meat in Broilers

Considering the remarkable implications exerted by the occurrence of wooden breast (WB) abnormality on meat tenderness and marketability, the poultry processing industry demands the implementation of postmortem procedures that can improve the textural traits of chicken breasts affected by this defect. Within this scenario, this study aimed at exploring the effectiveness of high-intensity ultrasonication (HIU) in attenuating the toughness of WB fillets and evaluating its effects on the main technological properties and quality characteristics of chicken breast meat. Overall outcomes showed that HIU significantly reduced (P&amp;lt;0.01) the compression forces of both unaffected and WB raw meat without negatively affecting the main meat quality traits and technological properties, such as color and water holding capacity. The significant (P&amp;lt;0.05) increase in myofibrillar fragmentation index (MFI) observed in unaffected fillets might hint at an alteration of myofibril integrity following the mechanical action of ultrasonic waves. However, despite the effectiveness of HIUin improving the textural traits of raw WB meat, overall outcomes obtained through western blot and MFI analyses suggested that HIU did not remarkably alter the microstructure of myopathic muscles. The myodegenerative lesions typically occurring in WB muscles may have partially disguised the mechanical effects of ultrasonic waves on muscle cells’ structures, making the elucidation of the mechanisms that lead to the softening of WB meat particularly complex.

Filter sterilized carcass rinsate for recovery of Salmonella species with various concentrations of cetylpyridinium chloride.

Controlling Salmonella in poultry processing continues to be important to processors and consumers. Cetylpyridinium chloride (CPC) has proven to be effective in vitro in controlling Salmonella. This study evaluated the recovery of Salmonella after overnight storage in 4°C filter-sterilized carcass rinsate containing CPC from 0.44 to 909 ppm (μg/mL). Ten Salmonella serotypes (18 strains), of which 6 serotypes are commonly isolated from poultry products, were grown in Bacto-Tryptic Soy Broth overnight at 37°C. Serial dilutions of a CPC/propylene glycol solution were prepared in 24-well tissue culture plates containing filter-sterilized carcass rinsate. Approximately 107 cfu/mL of each Salmonella serotype was added to the appropriate wells. Inoculated plates were stored overnight at 4°C. After storage, triplicate plates of brilliant green agar with sulfapyridine (BGS) were surface inoculated with 10 μL of the contents for each well, streaked for isolation, and incubated at 37°C for 24 h. Three replications were conducted. The presence of typical colonies on BGS plates was recorded as growth and verified through biochemical and serological testing. Of the serotypes chosen, Salmonella Kentucky, Dublin, and Enteritidis were the least resistant to CPC with a median minimum inhibitory concentration (MIC) of 14.22 μg/mL (range from 3.55 to 56.88 μg/mL); S. Typhimurium demonstrated a median MIC of 114.00 μg/mL (range from 28.44 to 114.00 μg/mL). Residual CPC potentially remaining attached to a carcass or in the weep after processing could potentially alter which Salmonella serotype is recovered from a carcass rinse due to different growth patterns during regulatory testing, with a potential for more virulent strains not to be recovered.

Enzymatic hydrolysis of minced chicken carcasses for protein hydrolysate production

Animal and poultry processing generates significant volumes of by-products that can be further processed for other uses. In this study, we treated minced chicken carcasses with proteases to produce protein hydrolysates that can be used as nutritional and/or flavor-enhancing ingredients. Five different microbial proteases were investigated for their abilities to hydrolyse the minced chicken carcass: Flavourzyme, Protamex, PB01, PB02, and PB03, with PB02 demonstrating the highest degree of hydrolysis (DH) of the minced chicken carcass (43.95%) after 4 h of hydrolysis. The essential hydrolytic parameters were optimized using response surface methodology in conjunction with Box-Behnken design. The optimal conditions were found to be: enzyme/substrate ratio of 3:100 (w/w), temperature of 51.20°C, pH of 6.62 ± 0.05, and substrate/water ratio of 1:1 (w/v) for 4-h hydrolysis, which resulted in a maximum DH of 45.44%. The protein recovery was 50.45 ± 2.05%, and the protein hydrolysate was high in free amino acids (7,757.31 mg/100 mL), of which essential and taste-active amino acids accounted for 41.74% and 92.64%, respectively. The hydrolysate was comprised mainly of low molecular weight peptides (1-5 kDa, 0.5-1 kDa, and <0.5 kDa), which were potential taste substances and flavor precursors. The resulting hydrolysate might be employed as a nutritive product, an ingredient for flavoring generation or a component of fermentation media.

Enforcement of US antitrust law in labour markets

In recent years, the US government has begun to focus antitrust enforcement efforts on labour markets. In 2022, for example, the Department of Justice (DOJ) blocked Penguin Random House’s acquisition of Simon & Schuster based on the theory that the merger would reduce compensation for authors.1 In the same year, the DOJ settled a lawsuit with three poultry processing plants that allegedly exchanged information on compensation of plant workers for the purpose of collaborating on pay decisions.2 The DOJ has also brought several criminal complaints against firms and individuals for fixing wages and agreeing not to poach one another’s employees, and it has intervened in numerous private cases to express its views on the application of antitrust to labour markets.3 The Federal Trade Commission (FTC) has also gotten involved. In 2020, the FTC submitted a filing before a state commission criticizing a hospital merger that it predicted would lower the wages of nurses.4 In 2023, the agency forced several companies to drop covenants not to compete that it had imposed on their employees.5 And in the same year, the FTC proposed a rule banning covenants not to compete.6 The two agencies are also reportedly planning to include a section on labour markets in their updated merger guidelines.7 Private antitrust litigation against employers is also flourishing.

USDA funding to expand meat, poultry processing options

USDA funding to expand meat, poultry processing options

Gelatin production from Turkey (Meleagris gallopavo) skin as a new source: From waste to a sustainable food gelling agent.

Turkey skin, a byproduct of poultry processing, contains a significant amount of collagen that might be used to make non-mammal gelatin. However, gelatin production from turkey skin has not yet been investigated. The purpose of this research is to figure out the optimum gelatin extraction conditions from turkey employing the central composite design (CCD) and response surface methodologies (RSM). The independent factors such as temperature (50, 60, and 70 °C) and time (5, 7, and 9 h) were optimized for three response variables, namely yield, gel strength, and foam expansion (FE). With R2 values of 0.8576 for yield, 0.8386 for gel strength, and 0.9283 for foam expansion, linear, quadratic, and respective models were used. The yield, gel strength, and FE actual values were found to be 15.36%, 396.61 g, and 40%, respectively. The optimum extraction conditions were found to be 62.90 °C for 6.84 h. The foam stability, L, and b values were significantly impacted by temperature and extraction time (p < 0.05). The gel strength value of the gelatin extracted under optimal conditions was higher than that of commercial bovine. The findings of this investigation showed that turkey skin is a suitable raw material for the manufacturing of gelatin. This article is protected by copyright. All rights reserved.

Prevalence of foodborne viruses and influenza A virus from poultry processing plants to retailed chickens

IntroductionFoodborne viruses are a serious concern in public health. This study investigated the prevalence of eight foodborne viruses norovirus (NoV), adenovirus (AdV), sapovirus (SapoV), astrovirus, hepatitis A virus (HAV), hepatitis E virus (HEV), rotavirus, aichivirus, and influenza A virus (IAV).Material and methodA total of 316 chicken samples were collected from three poultry processing plants to commercial markets (local and online). RT-qPCR- and PCR-positive amplicons obtained from monitoring were confirmed by sequence analysis.ResultsFoodborne viruses and IAV were not found in poultry processing plants. Of the 100 chickens purchased from the local and online markets, 19 (19.0%) AdV and 2 (2.0%) SapoV were detected. NoV, astrovirus, HAV, HEV, rotavirus, aichivirus, and IAV were not detected in the retailed chickens. Phylogenetic analysis identified 18 human AdV-41, one porcine AdV, and two SapoV-GI.1. It was the first case of the discovery of the SapoV gene in chicken. The average contamination level of detected AdV was 2.4 log DNA copies/g, but there were cases where the highest level was 5.35 log DNA copies/g.DiscussionThis study highlights the importance of chicken's contribution to the transmission of AdV with the possibility of annual variability with emerging symptoms. The prevention of AdV contamination in the food chain from slaughterhouses to retail markets should be monitored and controlled in further study.

The effects of novel alginate-lauric arginate coatings with temperature on bacterial quality, oxidative stability, and organoleptic characteristics of frozen stored chicken drumsticks

Although alginate has been reported to be used as an edible film and coating in food, to the best of our knowledge, this study is the first to investigate the individual effects of coatings, temperatures, storage times, as well as their interactions, on the bacterial quality, deterioration criteria, and sensory attributes of chicken drumsticks. To accomplish this, six groups of chicken drumsticks were treated with different coatings, temperatures, and storage conditions. The groups included 2 % alginate at 25 °C (Alg25) and 50 °C (Alg50), a mixture of 2 % alginate and 2 % LAE at 25 °C (M25) and 50 °C (M50), besides control untreated samples in distilled water at 25 °C (C25) and 50 °C (C50). The chicken drumsticks were stored at −18 °C for 3 months. The results showed that all treated chicken drumsticks induced a significant reduction in all bacterial counts, as well as a significant decrease in pH and thiobarbituric acid values, with an improvement in all sensory attributes, particularly in the M25 and M50 coated samples compared to the C25 and C50. Furthermore, exposing alginate and LAE to a temperature of 50 °C can increase their antimicrobial activity. In conclusion, the innovative combinations of LAE and alginate can be used successfully to decontaminate chicken carcasses in poultry processing plants.

A Sequential Membrane Process of Ultrafiltration Forward Osmosis and Reverse Osmosis for Poultry Slaughterhouse Wastewater Treatment and Reuse

To address some challenges of food security and sustainability of the poultry processing industry, a sequential membrane process of ultrafiltration (UF), forward osmosis (FO), and reverse osmosis (RO) is proposed to treat semi-processed poultry slaughterhouse wastewater (PSWW) and water recovery. The pretreatment of PSWW with UF removed 36.7% of chemical oxygen demand (COD), 38.9% of total phosphorous (TP), 24.7% of total solids (TS), 14.5% of total volatile solids (TVS), 27.3% of total fixed solids (TFS), and 12.1% of total nitrogen (TN). Then, the PSWW was treated with FO membrane in FO mode, pressure retarded osmosis (PRO) mode, and L-DOPA coated membrane in the PRO mode. The FO mode was optimal for PSWW treatment by achieving the highest average flux of 10.4 ± 0.2 L/m2-h and the highest pollutant removal efficiency; 100% of COD, 100% of TP, 90.5% of TS, 85.3% of TVS, 92.1% of TFS, and 37.2% of TN. The performance of the FO membrane was entirely restored by flushing the membrane with 0.1% sodium dodecyl sulfate solution. RO significantly removed COD, TS, TVS, TFS, and TP. However, TN was reduced by only 62% because of the high ammonia concentration present in the draw solution. Overall, the sequential membrane process (UF-FO-RO) showed excellent performance by providing high rejection efficiency for pollutant removal and water recovery.

Sustainability process innovations resulting in new value-added byproducts: principal lessons from second-order system-dynamics engineering (SOSDE)

Purpose Second-order system-dynamics engineering (SOSDE) involves constructing and running enterprise manufacturing simulation models with new proposals for operational processes, byproducts, supply chain and/or downstream marketing designs. This paper aims to describe sustainability the principal lessons from enacting SOSDE research for achieving goals in large manufacturing firms. Design/methodology/approach This study is a case research commentary in the agricultural industry that contributes abductively derives six principal lessons from SOSDE research on introducing sustainability-focused manufacturing and product innovations. Operational processes in large-scale poultry processing plants in an emerging market represent the specific industry and firm domain of this case study. Alternative SOSDE simulation models of decisions, materials flow and outcomes with versus without operational innovations were constructed following one-to-one interviews with experienced farm managers and entrepreneurs. Findings The principles demonstrate how large farms in a developing nation (i.e. Bangladesh) go about adopting radically innovative manufacturing, supply chain and marketing operations to improve traditional operations. This study confirms and expands on the general observation that SOSDE can help achieve sustainability and environmental, social and governance goals, contribute new value outcomes by converting unused production wastes into valuable byproducts and introduce design efficiencies in production, supply chain and marketing processes. SOSDE complements, while being a revolutionary departure from, “six sigma management programs” that focus on achieving exceptional and near mistake-free manufacturing operations. Both represent distinct philosophies and sets of actions that sometimes can conflict with one another. Embracing both successfully in the same enterprise is a goal that may appear unreachable, seemingly impossible to achieve and yet represents a manufacturing/marketing epitome that is observable in exceptional enterprises. Research limitations/implications This paper may generate controversy as well as advance interest in applying SOSDE in introductions of improved manufacturing, supply chain and marketing operations aiming to accomplish radical improvements in sustainability goals. Practical implications This commentary describes how using SOSDE and running alternative production simulations with versus without including superior, radically new, process innovations enable the firm to find and eliminate glitches in system changes and reduce the fear associating with breakdowns and financial losses due to inadequate knowledge of operating new industrial procedures and outcomes. Social implications Introductions of superior radically new innovations in industrial manufacturing and marketing via SOSDE frequently include manufacturing firms embracing new environment sustainability objectives and additional marketable byproducts from the firm's main productions lines. This commentary offers details on how this process is enacted in poultry manufacturing in an economically emerging nation. Originality/value Running simulations in SOSDE research offers a low-cost, fast and in-depth method to test “what-if” impacts of enhanced and radical innovations into product/service manufacturing operations – benefits supporting the recommendation to apply systems dynamics in business and industrial marketing.