Collaboration is key in successful poultry processing

Fostering a spirit of collaboration from preslaughter through to product dispatch can help to ensure that poultry processing plants maximize their output.

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collaboration-graphic
For high performing companies, collaboration is key. It is in the DNA of company culture. EtiAmmos | Shutterstock.com

From hatching eggs to processed birds, the broiler industry comprises a series of synchronized tasks. Each of these activities has its own targets that must be met or improved upon. Too often, however, these activities are viewed in isolation without consideration for what comes next.

Working with a culture of collaboration, however, can help to ensure that no activity is viewed in isolation and that due consideration is given to subsequent tasks, helping to ensure that overall goals are met.

For high performing enterprises, collaboration is key. It is in the DNA of company culture. Where this culture succeeds is when each section leader gives up their comfort zone and attachment to personal power to focus on the collective good.

Forming a Multidisciplinary Operational Management Group (MOMG) can go a long way in helping to ensure the correct functioning of a culture of collaboration, and there are a number of situations where implementing this culture can be particularly beneficial.

Given that the raw materials in poultry processing are living birds, what happens during pre-slaughter can have a significant impact on what happens at the plants, so collaboration must start on the farm.

Preslaughter

At this final rearing phase, there should be a team of experts that understand the basics of avian anatomy and physiology. Birds are only a few hours away from being transformed into meat, and companies should ensure that a supervisor is in place to guarantee that they are handled with care and not harmed.

Birds will have become accustomed to the peaceful conditions of the broiler house. Any risks that their changing circumstances may damage their quality and performance must be minimized.

When capture occurs, harvester behavior must be monitored. It must be ensured that the harvesting team walks slowly so that birds remain calm, and that birds are caught by the legs or body without harming them.

Cages must be in a good state of repair with no sharp edges and an appropriate size for the weight of the birds. If cages are not of the right size and the truck driver that takes the caged birds to the plant is careless, birds will be thrown around and harmed.

Wing flapping

Broilers’ natural reaction to the stress of too much noise or light is to flap their wings. This can result in bruising to the wings and bleeds in the breast. Studies have found that 40% of wing, breast and leg damage occurs at pre-slaughter.

Dead on arrival

The vehicles that transport birds to the processing plants have a series of adaptations to make them suitable for broiler transport. Nevertheless, in particularly hot or cold weather the number of dead on arrival birds can increase if proper precautions are not taken.

Those involved in activities prior to the birds reaching the processing plant must work together to minimize losses. If the farm manager, house managers, the harvesting crew and truck drivers do not collaborate, share knowledge and monitor each other’s activities, it will not be possible to keep losses to a minimum.

At the processing plant

In many companies, the oversight of the farm manager extends into the processing plant through a representative. These representatives may, for example, evaluate that feed withdrawal has been properly conducted through inspecting fecal matter in the lairage. A poor feed withdrawal may also become apparent during evisceration, or on exiting the pluckers.

The representative may also look for damage to birds that may have occurred as a result of poor harvesting or transport.

This representative needs to form part of the MOMG so that information can be shared both forwards and backwards.

Along the line

There are many other areas where the MOMG can bring its shared focus into play.

For example, in ensuring that birds are hung properly, with the aim of reducing bruising, or preventing flapping en route to the stunner.

Another challenge for the group is to ensure that birds do not suffer pre-shock immediately prior to entering the stunner. This results in intense wing flapping that can lead to wing bruising and dislocation and breast bleeds.

Similarly, careful checks need to be made to the scalding tank. Water levels must be constant throughout the day and temperature variation kept to a minimum. There must be sufficient water turbulence to loosen the feathers if difficulties are not to occur during plucking. The surface heat that birds gain during scalding must be preserved during the journey to the first plucker.

Workers Processing Plant

From start to finish, the various operations conducted at the poultry processing plant need to be carefully coordinated as without constant collaboration, goals will be harder to meet. capa55 | Shutterstock.com

 Plucking

The MOMG should understand at least the basic anatomy of chickens and that to achieve a good pluck, natural rubber fingers of varying degrees of hardness are required. Its members need to ensure that birds are efficiently plucked with minimal damage to the skin, that wings are not dislocated and that fingers are not wasted.

When all processing plant employees work within a culture of collaboration, losses and operating expenses are reduced, and output of competitively priced Grade A chicken is maximized.

 

Avoiding common pitfalls in poultry processing monitoring

www.WATTAgNet.com/articles/44269 

 


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