EQUIPMENTS USED IN MEAT AND POULTRY INDUSTRY

Submitted by-Sibo Boro(FPL14014)Nabendu Das(FPL14018)Girija Brahma(FPL14015)Ninja Begum(FPL14017)

CONTENTSI. Meat processingII. Equipments used in meat processing1. Two different cutting system2. Bowl cutter(bowl chopper)3. Piston stuffer4. Clipping machine5. Smokehouses 6. Combined equipment7. Brine injector8. Tumbler/massager9. Vacuum packaging machine10. Mixer/blender11. Emulsifying machine12. Frozen meat cutter

I. Poultry Introduction1. Electric water bath stunner2. Killing machine3. Hot water scalder4. Feather plucker machine5. Head puller6. Rotary foot unloader7. Carcass and foot unloader8. Vent cutter9. Eviscerator10. Evisceration trough11. Inside carcass washer12. Neck breaker13. Screw chiller14. Water dripper15. Packing machine16. Shackle washer

MEAT PROCESSING

Meat processing involves a wide range of physical and chemical treatment methods, normally combining a variety of methods. Meat processing technologies include:

Cutting/chopping/comminuting (size reduction) Mixing/tumbling Salting/curing Utilization of spices/non-meat additives Stuffing/filling into casings or other containers Fermentation and drying Heat treatment Smoking

EQUIPMENT USED IN MEAT PROCESSING: In modern meat processing, most of the processing steps can be mechanized.

The major items of meat processing equipment needed to fabricate the most commonly known meat

products are listed and briefly described hereunder.

MEAT GRINDER (MINCER) :

A meat grinder is a machine used to force meat or meat trimmings by means of a feeding worm

(auger) under pressure through a horizontally mounted cylinder (barrel).

A cutting system consisting of star-shaped

knives rotating with the feeding worm

and stationary perforated discs (grinding plates).

If frozen meat and meat rich in connective tissue

is to be minced to small particles, it should be

minced first through a coarse disc followed

by a second operation to the desired size.

TWO DIFFERENT CUTTING SYSTEM:

I. The “Enterprise System” :

Used in smaller meat grinders with orifice

diameters upto 98 mm and consists of

one star knife, sharpened only on the side

facing the disc, and one grinder plate.

Hole diameters varies from 13 to 5 mm

II. The “Unger System”:

Used in meat grinders with orifice diameters

up to 440 mm and consists of the kidney plate,

one or two cutting knives (star knives)

sharpened on both edges and one or two

grinder plates

BOWL CUTTER (BOWL CHOPPER):

Meat chopping equipment designed to produce small or very small lean meat and fat particles. consists of horizontally revolving bowl, curved knives rotating vertically on horizontal axle at high speed upto 500rpm.

Equipped with strong cover which protects against accidents and design plays crucial role in the efficient of the chopping process by routing the mixture flow.

Equipped with thermometer.

Modern large scale operate under vacuum, helps to improve color and texture by keeping oxygen out of meat mixes and avoid air pockets.

PISTON STUFFER: Used for filling all types of meat batter in casings,

glass jars, cans, etc.

A piston is moved inside a cylinder forcing the meat

through the filling nozzle into the containers.

Sometimes simple hand-held funnels are used to push

meat mixes into casings.

Modern filling machine for large operation designed as

continuous vacuum stuffers, enclosed air is removed

from the product, improve color and texture of finished

product.

CLIPPING MACHINE: Small aluminium sealing clips the

sausage ends.

Casing brakes slow release the shirred

casings from filling horns ensuring tight

filling. Then filled casing segment are

clipped in portions.

Generally used in large operation and

mostly operated by compressed air.

For medium-scale, manually operated

hand clippers are used.

SMOKEHOUSES

Tradition and small –scale operation:

Burning damp hardwood sawdust,

heating sawdust or log, etc.

Modern smoke generation:

Burning/smouldering of saw dust

Smoke generation through friction

Smoke generation through steam

COMBINED EQUIPMENT:

Modern facilities can combine smoking, cooking and cooling operations and continuous

process.

Parameter: Temperature upto 100 ºC and RH upto 100%.

Refrigerated Units: as fermenting/ripening room for first crucial steps in production of

fermented sausages/ram ham products (air temperature and air humidity accurately

controlled).

BRINE INJECTOR

Serve for injection of brine into meat.

Brine is water containing dissolved salt and curing substance as well as additives

such as phosphates, spices, sugar, soya protein, etc.

Injection is done by introducing pointed needless into the muscle tissue.

Brine injection mainly used for various types of ham, bacon and whole muscle

products.

Brine injector should be cleaned and disinfected regularly.

Before the injector is used, again all holes and needles should be rinsed with warm

water to avoid blockage of needle hole.

TUMBLER/MASSAGER Rotating drum with steel paddles inside

slowly moves meat causing mechanical

massaging effect.

Salt and phosphates are added to

achieve equal brine distribution and

liberates protein extraction.

Tumbler temperature below 10ºC to

avoid microbial growth

Tumbler temperature below -1º C, best

temperature to extract soluble protein

from muscle meat.

VACUUM PACKAGING MACHINE

Meat product placed in vacuum bag.

Air is removed from bag by vacuum

packaging machine and sealed.

Mixture of gas is injected evacuating the

air, inhibit bacterial growth, stabilize the

meat color.

Gas used are CO2 and N2.

MIXER/BLENDER:

To blend meat and spices, or coarse

and finely chopped meat.

Consists of parallel shafts .

Various paddles mounted in shaft to

mix meat.

Discharged through tilting by 90

degree the meat.

Vacuum mixer are also use to mix

under vacuum, helps in development

of desirable product color and texture.

EMULSIFYING MACHINE:

For very fine meat emulsion.

Functional parts are perforated plate,

attached to which two edged blades are

rotating.

Centrifugal pump forces pre-ground meat

through perforated plate.

Emulsifier operates at higher speed then

bowl cutter, produce finer emulsion-like

mix.

FROZEN MEAT CUTTER: It makes frozen meat suitable for

immediate comminuting in grinders, bowl

cutter, etc. without previous thawing.

Two types of machine used either

1. With knives cutting in vertical direction or

2. Using rotating drums with attached sharp

knives.

Hardest frozen product can be cut by

knives cutting in vertical direction.

POULTRY INTRODUCTION Poultry are domesticated birds kept by humans for the eggs they produce,

their meat, their feathers, or sometimes as pets. The word "poultry" comes from the French/Norman word poule, itself

derived from the Latin word pullus, which means small animal. Poultry is the second most widely eaten type of meat in the world,

accounting for about 30% of total meat production worldwide compared to pork at 38%.

Sixteen billion birds are raised annually for consumption, more than half of these in industrialized, factory-like production units.

Global broiler meat production rose to 84.6 million tonnes in 2013. The largest producer country is USA, followed by China and India has 5th

rank. Poultry is available fresh or frozen, as whole birds or as joints (cuts),

bone-in or deboned, seasoned in various ways, raw or ready cooked.

THE ELECTRIC WATER BATH STUNNER

The electric water bath stunner is designed

for stunning birds with electric current before

slaughtering. The use of a stunner with

appropriate parameters ensures proper and

humane poultry slaughtering.

The electric water bath stunner is made of

stainless, acid-resistant materials and welded

polypropylene panels.

The control box with electronic display is

based on electronic components.

The stunning electrodes will induce an

electrical current of sufficient intensity to

disrupt the neurotransmitters in the brain.

KILLING MACHINE The first step in processing poultry after you catch

the birds is a method to restrain the bird in order to kill it humanly. Kill cone’s or a stunning system is the best option for small operators.

Birds should be bled as soon as possible, within 15 seconds of stunning.

A knife is used for cut the jugular vein and carotid vain.

A sharp, clean knife should be used to cut across the front of the neck just below the head.

Turkeys and geese must be allowed to bleed for a minimum of two minutes, and other birds for one and a half minutes, before plucking and evisceration can begin.

Note : If bleed times lower than 60 seconds raise the concern that birds might not exsanguinate prior to entering the scalder or longer bleed times (>120 sec) tend to lead to feather picking difficultly due to increasing feather set post-exsanguination). http://www.poultry.uga.edu

HOT WATER SCALDER The poultry scalder is made of stainless, acid-

resistant materials. 

It is done by  immersion in tanks of hot water

known as hot water scalder.

Penetration of water between feathers is

facilitated by pumps, placed in the scalder.

Carcass scalding can be either soft - 55°C, for

around 2 to 3 minutes to produce yellow-skinned

birds - or hard - 57°C upwards for around 2

minutes for production of white-skinned birds.

These turbines not only allow hot steam to

escape from the scalder but also pump it into

water again to provide thorough stirring.

FEATHER PLUCKER MACHINE The combined washer and picker is designed for

thorough cleaning of carcasses of loose feathers and other remainders of processing in in-line pickers.

The combined washer and picker is constructed entirely of stainless, acid resistant materials.

Two casings are mounted symmetrically to a robust framework, with shafts fitted with special rubber fingers (the so-called whips), 265 mm long each. 

Poultry carcasses are transported in shackles of the overhead conveyor between axial guides, which double as spraying collectors.

The counter-rotating shafts with rubber fingers and the water spray shower from the collectors ensure thorough washing and clean the feathers left over from basic picking operations as well as other impurities

HEAD PULLER The head puller is used for removing chicken

heads after their necks are cut.

It is made of stainless, acid-resistant materials.

It is designed for continuous operation in typical

poultry slaughtering lines (it is usually placed

after the picking machinery).

The machine is equipped with its own drive unit,

consisting of a gear-motor.

The machine design allows for angular adjustment

of the pulling guides, as well as height adjustment

by means of a hydraulic lift, which makes it

possible to match the size of processed birds.

ROTARY FOOT UNLOADER The Leg Unloader is situated behind the

hock cutter in the killing line. The cut-off legs are safely pushed off the

shackles by stripping units. Brushes beneath the stripping units

prevent the legs from falling back into the shackle.

The shackles can be adjusted precisely to also ensure excellent results for layers.

The machine is a 180° version and yields a very high unloading result of up to 99% of legs.

It is also recommended that shackles should be connected with a stainless chain.

CARCASS AND FOOT UNLOADER The unloader is a mechanical,

operator less device, designed for unloading processed poultry carcasses or feet.

The unloader is made of stainless, acid-resistant materials and food approved plastic.

The unloader is mounted to a straight section of the overhead conveyor, where the processing cycle has finished and shackles must be emptied.

The unloader is designed to work with rack shackles.

VENT CUTTER The vent cutter is designed for

cutting and extracting vents

from poultry carcasses.

The vent cutter is made of

stainless, acid-resistant

materials.

. The cylinder blades are line

driven and after each cycle,

cylinder blades are then cleaned

by water.

EVISCERATOR

EVISCERATION TROUGH Evisceration troughs are used in manual

poultry evisceration lines and are designed

for transporting the evisceration offal.

The length and width of the trough is

adapted to the size and quantity of

processed poultry.

On the rim of the trough, there are tables

for tools and water valves with 10-second

time-lag switches which ensure

economical water usage.

INSIDE CARCASS WASHER The inside washer is designed for cleaning

the inside of carcasses after the evisceration

process.

Holes drilled in the pipe provide proper

spraying after supplying water into the

carcass. The washing part is finished with a

handle. After inserting the pipe into the

carcass, water is supplied by pressing the

button on the handle.

Releasing the button disconnects water.

Water is delivered to the washer through a

10mm hose.

NECK BREAKER

The neck breaker can be retrofitted into

any evisceration line and can be supplied

for various processing capacities by

providing the required number of working

units and shackle distances.

Adjustable breaking units allow easy

adjustment to any bird size as well as to

produce birds without neck & to leave the

neck into the neck skin after the breaking

process.

The open design of the neck breaker

ensures easy cleaning.

SCREW CHILLER Screw Chillers are made of food

grade stainless steel. This equipment is used to chill the

bird after the process of scalding and de-feathering so that it can be made ready to be stored.

A screw with adjustable speed transports the birds gently through the water bath.

By constantly blowing air into the bottom area, good mixing of the water and even cooling of the birds is ensured.

WATER DRIPPER

PACKING MACHINE

SHACKLE WASHER The shackle washer is designed for

washing shackles of overhead conveyors

in poultry slaughtering plants.

The shackle washer is made of stainless,

acid-resistant materials, and the brushes

are made of plastic. Shackles transported

by the overhead conveyor are placed

between concurrently rotating brushes and

washed by water sprayed from nozzles.

Brushes are powered by 0.37 kW electric

motors through a motoreducer. 

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