Poultry processing involves stunning, killing, bleeding, scalding, plucking, evisceration, washing, and cooling before the bird is cut, aged, and packaged. The process aims to prevent contamination and produce high-quality meat.
Precise steps in poultry processing prevent contamination and produce a bird that isn’t tough or marred by skin blemishes. Poultry undergoes stunning, killing, bleeding and scalding processes before the sebaceous glands, feet and head are removed. After the birds have been washed, they are quickly chilled before being cut, aged and packaged for distribution.
The birds are usually crated and transported to poultry processing plants, where they are kept in ventilated and misted holding areas. Sometimes a special blue light is used to keep the birds calm once they hang on the racks by the stunning step, because the flapping of their wings can cause internal bleeding that discolors the flesh. Birds are commonly plunged into salt water with an electric current that renders them unconscious for a minute or two. Radon gas is used in some regions to stun poultry, but is considered more expensive.
The short time a bird remains unconscious gives the processing plant enough time to kill it and allow it to bleed out. Blood drainage prevents the meat from appearing dark. In large poultry processing plants, blood is treated as a waste product and a pollutant.
The birds then move to scalding tanks, where the hot water loosens the feathers for harvesting. It’s important to keep the water temperature regulated to avoid cooking the bird. The water also needs to be changed frequently to avoid contamination. After blanching, poultry is kept moist so that the skin does not start to darken.
Plucking, or harvesting, is commonly done by machine in large processing plants. Birds are placed in rotating drums fitted with rubber-like fingers that remove feathers through abrasion. Any remaining pinfeather can be waxed to make it easier to remove. In some poultry processing operations, the beautiful pin feathers are scorched.
The next step involves evisceration, the removal of the head, feet and sebaceous glands located on the top of the bird’s tail. Machines commonly sever the head, while the feet are severed at the knee joint. Birds use the sebaceous gland to preen their feathers, but it contains a bad smell and taste. Food safety regulations commonly require that the entrails remain beside the bird during this part of the process so that an inspector can examine the inside and out for disease. A torn intestine can contaminate meat, but some countries allow a chlorine wash to address the problem.
The poultry carcasses are then washed and cooled rapidly in cold water or with jets of cold air directly into the bird’s cavity. Air cooling of poultry is most common in Europe and Canada, but is a typical process for lamb, pork and beef internationally. The bird is now ready to be cut into pieces and boned. Poultry processing may include cutting, pressing and breading the meat for chicken nuggets, luncheon meats or hot dogs.
Curing takes a minimum of four hours to keep the meat tender before the poultry is frozen or consumed. The final stage of poultry processing involves weighing, labeling and packing. It is now ready for distribution to grocery stores for consumer purchase.
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