POULTRY PROCESSING

J.ILANGUMARAN

POULTRY PROCESSING
Receiving Stunning Halal Cut Scalding DeDe-feathering Cock head cutting Leg cutting EV Removing Chilling in chiller A Chilling in chiller B Packing Freezing at -35oc Storing in frozen stores Dispatch Transport

RECEIVING
The birds are received from their own farms, 10,000 birds are processed approximately per hour in one processing time.

STUNNING
The received birds are killed in the killing section by taking them to unconscious state. Normally the birds are not killed by cruel methods.

HALAL CUTTING
The Semi conscious birds are hanged in the hooks, then the heads of the birds are partially cut if they are to be exported to the Muslim countries. This cut is simply known as halal cut. The blood is collected in the blood bank by a receiver.

SCALDING
It is nothing but dipping the birds in the bath of hot water to pick the feathers of the birds. The temperature is maintained from 750c to 800c by using steam.

DE-FEATHERING
The feathers are picked up in a picking machine. There are number of wheels on both sides of the walls of the machine. The wheels are rotated opposite to each other by running the motor pulleys. The wheels have some projections just like fingers. These wheels are produced by rubber materials and tightly filtered in the wheel.

DE-FEATHERING
When the birds are entered in to the machine, the pulleys are rotated oppositely then the feathers are picked.

HEAD CUTTER
After Defeathering, the heads are cut by using the head cutter. In this, the head is removed from the body of the bird, the neck does not cut in the head cutter. It the neck is not needed it is removed by using the neck cutter.

LEG CUTTING
Now the birds go to the leg cutter. Here the legs are cut by using a circular shape blade. Then the birds are passed into the next section by a conveyer.

E.V. SECTION
Then the birds are sent to the E.V. section
by a conveyer and then the birds are hanged in the hooks.

DRILLING
In the E.V. section the birds go through the the driller. By using the hand drilling machine the portex is drilled for easily removing the unwanted portions. Then the body is easily separated with the help of knife.

SPOONING
In this spooning section the inner portions are just spooned out. Then the parts like brain and lungs are separated.

VACCUM CLEANING
By using a handheld vacuum pump the inner parts are cleaned, the dust and unclean feather are sucked by the vacuum cleaning.

SCISSORING
The unwanted portions of the skin is removed by the hand operated scissoring instrument.

GRAPH PULLING
The function of the graph pulling section is just similar to a driller. It consists number of tooth. When the birds are crossing this machine the teeth portions (or) the spindle rotate in both sides. At the same time the water is sprayed for cleaning in the inner portion of the body. Thus the body is cleaned. All the above operations are done in manually.

CHILLING IN CHILLER A
For the preservation purpose we must reduce the temperature. But we do not reduce the temperature suddenly. So we must reduce the temperature gradually. The first one is chiller A. In this chiller A we maintain a temperature at 12oc by using the chilled water. The temperature of the inner body of the birds will be approximately 50oc to 55oc. This temperature is reduced gradually.

COOLING IN CHILLER B
In this chiller B the body temperature of the bird is maintained at 0oc by using flake ice. The flake ice producing machine consists a hollow drum. The hollow drum includes another solid cylinder & through the solid cylinder the refrigerant is passing. At the top of the machine the water is sprayed on the outside circumference of the hollow cylinder.

COOLING IN CHILLER B
The sprayed water is cooled to 0oc and makes ice chips over the hollow cylinder surface. This ice particles are removed by a blade and the collected ice particles will goto the chiller B.

PACKING
When all the above processes are completed, the chicken will goto the packing section. In the packing section the weight of the bird is sensed by a sensor and then released from the hooks by a simple mechanism. Here the birds are packed on the basis of weight manually.

PORTIONING
The processed birds are portioned like lolly
pop, leg piece etc., and are packed separately to meet the requirements of the customers.

FREEZING
The processed and packed birds are frozen in three Blast Freezers. The chickens are placed in a shelf and stored in the blast freezers. In this Blast freezers the temperature maintained is -35oc to -40oc.

STORING IN FROZEN STORES

After crossing the blast freezers the birds are frozen and stored into the frozen storage units. In this the temperature at -18oc is maintained

TRANSPORTATION
The preserved birds are transported by containers to the local markets. In the container vehicles the -180c is maintained until it reaches the end customer for consumption, The processed chicken is having one year warranty.

PLANT CONSTRUCTION
The whole plant is controlled by a Panel Logic Controller. The capacity of the plant is normally 360 TR. They have a high stage compressor and two booster compressors.

THANKS TO ALL