Zinpro Russia Seminar - Optimizing Carcass Quality and Yield at the Processing Plant - Updating.pptx
1 like•30 views
The document discusses the importance of optimizing carcass quality and yield in poultry processing, emphasizing the relationship between poultry farms and processing plants. Key points include the significance of flock uniformity, feed withdrawal management, and operational practices that impact quality and yield. Additionally, the document highlights the economic consequences of inconsistencies and the necessity for farms to meet the plant's requirements for optimal performance.
Zinpro Russia Seminar - Optimizing Carcass Quality and Yield at the Processing Plant - Updating.pptx
- 1. 1 Optimizing Carcass Quality and Yield at the Processing Plant Eng. Fabio G. Nunes Poultry Processing Consultant, Brazil ZINPRO Broiler Carcass Quality Seminar
- 2. Our agenda will address... 2 Poultry Farms x Processing Plant Interaction Importance of Carcass Uniformity Feed Withdrawal Carcass Quality and Yield Carcass Cooling
- 3. In an integrated poultry processing company, the poultry farms are the supplier of the raw material to the plant; Therefore, the farms are the “start line” of the business, not its end, as often and mistakenly thought by themselves;
- 4. Farm Plant Under a customer-supplier operational relationship; What requires the farms fulfill the raw material’s requisites so as to guarantee, support the plant’s optimal (technical and economic) performance;
- 5. In such a context, farms’ daily agenda must address: Flock Uniformity Proper Feed Withdrawal Carcass Quality and Yield
- 7. Operational Parameter - Average LW - Does mean much! Out of Specs: How Much? What to Do? How Costly? Companies know how much money they make, but often don’t know how much more money could make! 7
- 8. Live Hanging Grip on Legs - Ununiform Hanging - Damage to Legs - Team Exhaustion Inconsistent Hock Cutting - Transferring, Eviing & Cutting - Manual Trimming (or Not) - Quality & Yield at Risk 8
- 9. Inconsistency - Ununiform Birds - Variable Resistance Economic Impact - Bloody Lesions & Fractures - Salvage and Downgrades Animal Welfare 9 Stunning
- 10. Scalding & Plucking Inconsistency - Breast Fillets Outlook - Yield - Subcutaneous Fat - Plucking Effectiveness Pluckers Setting - Damages to Skin, Wing, and Feet - Contamination 10
- 11. Evisceration Inconsistent Job - Damages to Carcasses - Visceras Fall-back - Contamination - Giblets Loss Economic Downside - Slower Killing Line - Salvage Up - Saleable Weight Down - Higher Operational Costs - Lower Competitiveness 11
- 12. 12 Madsen, T. G. and Pedersen J. R. Importance of flock uniformity – How can we improve it in broilers?, Evonik Degussa, April 2010; Brian Cosgrif, WattAgNet.com, July 1, 2009 Growing Automation = Equipment Tolerance Quality and Yield Standardized Products: Market Requirement Out of Specs: < 40% $ Uniformity: Priority Monitoring to Improve CV 8 (>80%) ≤
- 13. Feed Withdrawal
- 14. Bilgilli, 2002 Feed Withdrawal - Empty the GIS to lower the risk of contamination and salvage Shield the Carcasses Safety and Yield; TFT: Window 8h a 12h - Feed withdrawal ≥ ≤ thru Hanging
- 15. Higher Shrink = Lower Yield Contamination: Bile and Intestine - Salvage - Shelf Life Feed and Excrement Lower Carcass Yield Contamination: Salvage Shelf Life Papa C.M., Dickens J.A., 1989; Buhr, 2008; Bilgilli, 1997 y 2002 <08 h >12 h
- 16. ≥ 8h ≤12 h
- 17. *Oderkirk, A., Feeding and Feed Withdrawal Effects on Broiler Contamination, Poultry Fact Sheet, June 1, 1999; Buhr, 2008, Bilgilli, 2002 17 Feed Withdrawal: Inherent Shrink in Two Phases Real, silent, and unrecoverable loss! 0-6h off Feed: Emptying of GIS (0.3% - 0.6%/h) Out of companies’ control ≥ 6h thru Hanging: Glycolysis and Lipolysis Linear & Time-Dependent
- 18. Feed Withdrawal Length x Carcass Yield
- 19. Stan Savage, Feed Withdrawal - A Practical Look at Its Effect on Yield, October 1998; Julie Northcutt, Factors influencing optimal feed withdrawal Duration, UGA Cooperative Extension Bulletin 1187, Jan 2010; Buhr, RJ et. al., Influence of time off feed on broiler viscera weight, diameter, and shear, Poultry Sci. 1998 May;77(5):758-64 19 Days Days Days
- 20. Thompson and Applegate, 2006 20
- 21. Bilgilli, 2003 0 1 2 3 4 5 6 7 4 8 12 16 L ive S hrink (%) Hrs 10°C 32°C
- 22. 200,000 x 2.20 kg = 440,000 kg LW/d 440,000 kg x 0.10%/h = 440 kg/d 440 kg x 22 d = 9,680 kg/mo. 9,680 kg x 12mo. = 116,160 kg/[email protected]% 487,872 Your plant: 200,000bpd, 2.20 kg LW and 0.10%/h and 0.42%/h live shrink: How economically significant are such tiny live shrinks?
- 23. Brazil: Salvage - Contamination 2020 Your Plant 200,000 bpd x 3.30% = 6,600 birds x 2.50 kg x 73% = 12,044 kg/d 12,044 kg x 10% (DP) = 1,204 kg/d = 26,488 kg/mo = 318,000 kg/yr 23 Kindlein, L. using data from Brazil’s Ministry of Agriculture Federal Inspection Service, 2022
- 25. “Product or service free from defects” Phillip B. Crosby Philip Bayard "Phil" Crosby, (June 18, 1926 – August 18, 2001) was an American businessman and author who contributed to management theory and quality Quality
- 26. Expression of the birds’ genetic potential! (Dry Carcass Weight : Live Weight) x 100 1957 1977 2005 2014 1957 1977 2005 Aviagen Yield - Carcass
- 27. Measures how much of the birds’ potential saleable weight is harvested and converted into products at the plant; Expressed in percentage of the live weight, it is key! Yield - Processing
- 28. David Beavers,Three key areas for yield maximization in poultry processing; WattPoultry.com, Dec 19, 2012 “The processing plant is the only generator of economic results in an integrated poultry company”. Dr. S.F. Bilgili These results fully DEPEND on the Processing Yield, the most important economic drive; Plant’s mission consists of converting the totality of the carcasses yield into high-quality meat products at the least cost possible;
- 29. Quality & Yield Avian Health Nutrition Flock Management Catching, Hauling & Holding Processing
- 30. Avian Health Gut Health - Vital - Ensure Nutrients Absorption - Boosts Immunity & Health - Boosts Birds Development, Quality & Yield - Lower Production Cost & Higher Profitability Diseases - Depress Production and Productivity - Lowers Quality, Yield and Uniformity O. Morales, Brasil Sul de Avicultura, 2019
- 31. Supply the daily nutritional demand of the flock aiming at: • Enhance the genetic potential expression - Carcass Yield • Maximize the Development of the Noble Cuts • Maximize Flock Uniformity - Plant Operation & Sales • Contribute to Flock Health - Development and Profitability Nutrition
- 32. …Full, Strong Feathering University of Illinois Extension - Incubation and Embryology, https://web.extension.illinois.edu/eggs/res12- feathers.html Steve Leeson in World Poultry, 07-06-2021; https://www.poultryworld.net/specials/effects-of-nutrition-on- Skin protection against Lesions - Downgrade at Plant Thermal Comfort - Regular Feeding Nutrients Intake and Development Health Uniformity
- 33. Resist to Mechanical Aggression Minimizing Scratches & Cellulitis Preventing Downgrades & Salvage Point-of-Sale Appeal & Decision Strong, Nice-looking Skin... Bilgilli, 2012
- 34. Withstand Birds’ Growth Mobility: Water and Feed Access Resisting Processing Aggressiveness - Modern Lines: 15 thousand bph - Integrity of Carcass: ...and a Sturdy Skeleton!
- 35. Gregory, N. G., British Poultry Science (1990) 31: 53-58
- 36. 2019 2020 Brazil: Contusion & Fractures Salvage Kindlein, L. using data from Brazil’s Ministry of Agriculture Federal Inspection Service, 2022
- 37. Bilgilli y Hess, 1998; Villarroel et. al,, 2018; Harn, J.v, 2008; Summers, J. Tech Info 13; *EU Directive 2007/43/EC; ABPA, Protocolo de bem-estar para Frango de Corte, 2016, http://www.abpa-br.org; SD - Impacts - Quality and Yield - Flock Uniformity - FPD SD - Limits - BR 39 kg/m ≤ 2 - UE 33, 39 y 42 ≤ ≤ ≤ kg/m2* Flock Management & Stocking Density - SD
- 38. SD x Carcass Quality FPD Back Scratches Back Hematoma Wings Hematoma Villarroel et.al., 2018 SD
- 39. Transcript and adapted from Bilgilli & Hess, 1995; Distinct superscripts are statistically different SD x Carcass Yield SD (Kg/m2 ) Breast Fillet (%) Skin Lesion (%) % Grade A Carcasse s 29.2 14.0a 17.1b 52.3 31.9 13.9ª 26.8a,b 48.1 35.2 13.5b 38.1ª 46.2
- 41. Bilgilli, Risks and Benefits of Flock Thinning; Allen, V.M., et al, 2008; Koolman, L. et al., 2014 Pile-up and Flapping Green Muscle Development Wings and Skin Lesions Cellulitis Feed Withdrawal Competition = Back Lesions Lower Uniformity Lower DWG = Yield Campylobacter Catching Crew Crates /Containers Vehicles Flock Thinning
- 43. House Preparation Fowler & Merlor, 1975 24h Pre-Catching: 35% of the Lesions > 90% of the Salvaging - Obstacles on the floor, farmer walking, short staffing, and careless preparation of the house; The remainder 65% are from catching, hauling & plant;
- 44. Catching Feet Neck Body Severe Wings & Legs Intensity and Extension of the Lesions Moderate Wings: Internal Side Do not cause Lesion
- 45. J. Northcutt, Reference Guide for Solving Poultry Processing Problems, 2012 Bruises Sites 33% 42% 25%
- 46. 46 Live Catching: Wing Flapping and Crating Containers Unloading
- 47. 47 Internal side of the previous lesion Affects (mostly) heavy birds Slaughtering enhances its Appearance
- 48. 48 Catching: Wing Flapping Crating Container Unloading Hanging: Birds Uneasiness Comfort Line Sinuosity
- 49. 49 Pre (Bloody) or Post Slaughter Predisposition: Catching x Flapping Containers Live Hanging Obstacles along Line Defeathering: Installed Capacity Pluckers Setting Rubber Fingers Operator
- 50. 50 Stocking Density Flock Thinning Poor Flock Management Nutrition: Skin Strength (Collagen) Subcutaneous Fat Layer Predisposition: Scratches and Scars Scalding: Resources Time x Temperature Balance Defeathering: Resources Pluckers Setting
- 51. 51 The tendon can be weakened or damaged by staphylococcal (tenosynovitis) or reoviral infections, and can also be debilitated due to inactivity (lack of exercise) of the birds; D. V. Bourassa, WOGS, January 2017 Heavier weight birds are more likely to partial or total rupture of the gastrocnemius tendon; Rupture leads to hemorrhages that turn green in 48h;
- 52. 52 Lesion from Femoral Degeneration Fast or Slow Growing Birds Literature Available Catching: Method (Feet) x Live
- 53. DORSO CRANEAL MYOPATHY 53 S. F. Bilgilli, WOGS, Abril 2017 F. C. Zimermann (2008)* coined the term “Dorso Cranial Myopathy” to describe the degenerative changes associated with the ALD muscles. Lesions are often bi-lateral and includes mild petechial to severe hemorrhage, citrine color edema, thickening of the muscles, mild to severe necrosis, and fibrosis. The skin overlying the muscle is usually discolored (yellow-red) and can be easily detected by a trained eye on the processing line. Mild secondary inflammation may also be
- 54. Arikan, M.S. et al, Effects of Transportation Distance, Slaughter Age, and Seasonal Factors on Total Losses in Broiler Chickens; Brazilian Journal of Poultry Science; Jul - Sept 2017 / v.19 / n.3 / 421-428 Live Shrink: Season x Travel Distance <50 km 51-150km >150km Live Hauling
- 55. Thermal Comfort & Operation - Live Shrink - Bruises - Mortality Holding Shed
- 56. M. Petracci, D. L. Fletcher, and J. K. Northcutt; The Effect of Holding Temperature on Live Shrink, Processing Yield, and Breast Meat Quality of Broiler Chickens; 2001 Poultry Science Holding Shed x Live Shrink
- 57. 39 d 53 d 0 2 4 6 8 10 5.3 7.2 2 4.2 Stopped In Motion Holding Shed x Carcass Quality Incidence of Wings Bruises % Bilgilli & Hess, 1995
- 58. Thermal Comfort: Location, orientation, materials, dimensions, ventilation, and foggers; Operation: formally managed, and monitoring parameters temperature, RH and holding time, aiming at complying with animal welfare regulations and reduce the risk of mortality, live shrink and lesions; Monitoring: formal and systematic; corrective actions when necessary
- 59. https://www.inspection.gc.ca/food-safety-for-industry/food-specific-requirements-and-guidance/meat- products-and-food-animals/guidelines-for-stunning-techniques/eng/1538160892409/1538160892704#a11; https://www.meatinstitute.org/index.php?ht=a/GetDocumentAction/i/139926 Live Hanging Team Recognition Unloading Method of Hanging Project & Engineering - Overhead Conveyor - Ergonomics Maintenance
- 60. Stunning Complex and Risky • Equipment: Supplier Dimensions Resources • Skilled Operator • Maintenance • Validation
- 61. 61 Escalding & Plucking Time & Temperature - Yield - Subcutaneous Fat - 0,5% a 1,5% - Appearance
- 62. Evisceration - Abdominal Fat Leaf = 2 to 3% of carcass Weight - 200 thousand bpd x 2,5 kg x 73% = 365.000 kg - 365.000 kg x 2,5% = 9.140 kg/day
- 63. Neck: 1,3% to 1,6% LW Heart: 0,4% to 0,6% Liver: 1,9% to 2,5% Gizzard: 0,9% to 1,4% Total: 4,5% to 6,1% Meyn
- 64. Carcass Chilling
- 65. 65 Cool the Carcasses Rapidly Guarantee the Product Safety Optimize the Yield
- 67. 40 * Morris & Associates, Water Immersion Poultry Chilling - Advances in Technology, pág. 2, January 2012 Water Chiller - Water is Cheap and Available - Cooling Capability is 25x of the Air* - Efficient Washing, Cooling and Disinfection
- 68. 68
- 69. 69 M.B. Mielink et al., The Effect of Evaporative Air Chilling and Storage Temperature on Quality and Shelf Life of Fresh Chicken Carcasses, 1999 Poultry Science 78:1065-1073; H. Zhuang et. al., Effect of Dry-Air Chilling on Warner-Bratzler Shear Force and Water-Holding Capacity of Broiler Breast Meat Deboned Four Hours Postmortem; International Journal of Poultry Science 7 (8): 743-748, 2008 Air Chiller - Cold Air + Water Mist - Water Chiller + Cold Air
- 70. 70
- 71. 71 Nagyová A. et al., The efficacy of air spray chilling and its impact on microbial quality of broiler carcasses; Italian Journal of Animal Science 2015; 14:3740
- 72. 72 Hygiene, Disinfection and Yield Cooling Efficiency (f) ΔT Water + Air Water Chiller + Cold Air
- 73. 73
- 75. Farms must see themselves as raw material providers; As such, they must struggle to deliver live birds having plants’ requirements always in mind; Carcass uniformity must be hardly pursued, as it improves the operational performance (quality & yield) and bottom-line; Careful feed withdrawal management increases food safety and carcass yield, and reduces carcass salvage and costs;
- 77. 77