Apparatus and method of removing flesh from poultry

Abstract

An apparatus for removing a flesh portion from a poultry carcass comprising an elongate platform having a conveyor that is movable along a length of the platform. The conveyor comprises one or more poultry carcass attachments adapted for coupling the conveyor to the poultry carcass such that the poultry carcass is orientated with a breast flesh portion of the poultry carcass facing away from an upper surface of the platform. The apparatus further comprises at least one of a first cutting assembly configured to remove a breast flesh portion, and / or a second cutting assembly configured to remove a leg flesh portion. The first cutting assembly and / or second cutting assembly are arranged on the upper surface of the platform adjacent the conveyor whereby movement of the conveyor in a forward direction enables the first cutting assembly and / or the second cutting assembly to remove the flesh portion of the breast and / or leg.

Description

APPARATUS AND METHOD OF REMOVING FLESH FROM POULTRYTechnical Field

[0001] The present invention relates to a method for removing the flesh from a poultry carcass. The present invention also relates to an apparatus for removing the flesh from a poultry carcass.Background

[0002] Typically the breast flesh is severed manually from a poultry carcass by a combination of cutting and pulling. In such a method, the clavicle is removed carefully from its location in the poultry carcass where it is embedded in the breast flesh. The top of the clavicle is positioned near to the leading end of the sternum of the poultry.

[0003] When the clavicle and the breast flesh are removed manually a considerable part of the breast flesh is wasted because flesh often remains or sticks to the clavicle and its manual removal is time-consuming.

[0004] The present invention seeks to provide a method and apparatus for not only removing the breast flesh from a poultry carcass wherein the mentioned drawbacks do not occur but also to provide a method and apparatus which removes the thigh and leg meat during the same processing step. In addition, the present invention seeks to provide a method and apparatus that automates the action of removal of the flesh from a poultry carcass.Summary of the Disclosure

[0005] In a first aspect, embodiments are disclosed of an apparatus for removing a flesh portion from a poultry carcass. The apparatus comprises an elongate platform having a conveyor that is movable along a length of the platform. The conveyor comprises one or more poultry carcass attachments adapted for coupling the conveyor to the poultry carcass such that the poultry carcass is orientated with a breast flesh portion of the poultry carcass facing away from an upper surface of the platform. The apparatus further comprises at leastone of a first cutting assembly configured to remove a breast flesh portion of the poultry carcass, and / or a second cutting assembly configured to remove a leg flesh portion of the poultry carcass. The first cutting assembly and / or the second cutting assembly are arranged on the upper surface of the platform adjacent the conveyor whereby movement of the conveyor in a forward direction enables the first cutting assembly and / or the second cutting assembly to remove the flesh portion of the breast and / or leg.

[0006] In some embodiments, the poultry carcass attachment may comprise a saddle that is insertable within an orifice of the poultry carcass and a leg holder adapted for securing the legs of the poultry carcass. In some embodiments, the poultry carcass attachment may further comprise a hook adapted to project upwards and above an upper surface of the saddle, the hook being arranged on an opposing side of the saddle to the leg holder. In some embodiments, a distance between the hook and the leg holder may be adjusted. In some embodiments, the poultry carcass attachment may be arranged such that the poultry carcass is able to be supported substantially symmetrically on either side thereof. In some embodiments, the apparatus may comprise a plurality of poultry carcass attachments.

[0007] In some embodiments, the first cutting assembly may comprise a first cutting implement adapted to cut the flesh portion adjacent a wishbone of the poultry carcass. In some embodiments, the first cutting implement may be a pair of rotary disc knives. In some embodiments, the first cutting assembly may further comprise a pair of wishbone guides that are offset rearwardly from a leading edge of the rotary disc knives and that are adapted for separating the breast flesh portion away from the wishbone.

[0008] In some embodiments, the first cutting assembly further comprises a second cutting implement that is adapted to cut at least a majority of the remaining flesh of the breast flesh portion off the poultry carcass. In some embodiments, the second cutting implement may be a pair of curved knives. In some embodiments, the first cutting assembly may further comprise one or more skin removal hooks arranged to align behind a trailing edge of each of the pair of curved knives of the second cutting implement.

[0009] In some embodiments, the second cutting assembly may comprise a preparatory cutting assembly configured to make a series of preparatory incisions in and / or around the leg flesh portion, and a primary cutting assembly configured to cut and removethe leg flesh portion from the poultry carcass. In some embodiments, the conveyor may be adapted to move along the platform past the preparatory cutting assembly prior to the primary cutting assembly. In some embodiments, the preparatory cutting assembly may comprise a plurality of cutting implements, each of the plurality of cutting implements being elastically biased towards a resting configuration by one or more springs, whereby in use each of the plurality of cutting implements is able to engage and cut the leg flesh portion whilst pivoting around a bone and / or joint of the leg flesh portion so as to allow the leg flesh portion to pass thereby. In some embodiments, at least one of the plurality of cutting implements of the preparatory cutting assembly may be adapted to cut one or more of the sinews along between the flesh portion of the leg and a bone of the leg. In some embodiments, the primary cutting assembly may comprise one or more cutting implements adapted for cutting a remaining portion of the flesh of the leg flesh portion off the poultry carcass and one or more separation assemblies configured for removing the cut remaining portion of the flesh away from the one or more cutting implements. In some embodiments, the one or more separation assemblies may locate in front of the one or more cutting implements of the primary cutting assembly as the conveyor moves the poultry carcass in the forward direction. In some embodiments, the one or more cutting implements of the primary cutting assembly may comprise one or more of rotary knives and water knives. In some embodiments, at least one of the one or more cutting implements of the primary cutting assembly may be a water knife. In some embodiments, the primary cutting assembly may comprise a plurality of water knives, each water knife being configured to oscillate about an axis that extends substantially parallel to the forward direction of the conveyor, and each water knife being spaced from one another on either side of the conveyor. In some embodiments, the water knife may operate at a pressure between about 3000 psi to about 20000 psi. In some embodiments, the primary cutting assembly may further comprise a first set of augers adapted to grip and apply a tension force to the flesh of the leg flesh portion prior to engagement of the leg flesh portion with the one or more cutting implements of the primary cutting assembly. In some embodiments, the one or more separation assemblies may comprise a second set of augers adapted to grip and pull the remaining portion of the flesh away from the one or more cutting implements.

[0010] In some embodiments, the apparatus may comprise both a first cutting assembly and a second cutting assembly. In some embodiments, the conveyor may beadapted to move along the platform past the first cutting assembly prior to the second cutting assembly.

[0011] In a further aspect, embodiments are disclosed of a method of removing a flesh portion from a poultry carcass, the method including: coupling a poultry carcass to a conveyor moving in a forward direction wherein the poultry carcass is orientated with a breast flesh portion of the poultry carcass facing away from a surface of the conveyor; and moving the poultry carcass through one or more cutting assemblies wherein each of the one or more cutting assemblies removes a respective flesh portion from the poultry carcass.

[0012] In some embodiments of the method, the one or more cutting assemblies may comprise at least one of a first cutting assembly configured to remove a breast flesh portion of the poultry carcass, and / or a second cutting assembly configured to remove a leg flesh portion of the poultry carcass. In some embodiments, the poultry carcass may be de-winged prior to the coupling of the poultry carcass to the conveyor. In some embodiments, the method is performed using an apparatus as described in the first aspect.

[0013] In yet a further aspect, embodiments are disclosed of an apparatus for removing a flesh portion from a poultry carcass. The apparatus includes a conveyor in the form of an endless belt and moveable in a forward direction, a poultry carcass attachment assembly fixed onto the conveyor, the poultry carcass attachment assembly adapted for attaching a poultry carcass to the conveyor whereby a breast flesh portion of the poultry carcass faces away from the surface of the conveyor when attached thereto, a first cutting assembly for cutting a breast flesh portion off the poultry carcass, and a second cutting assembly for cutting a leg flesh portion off the poultry carcass. In some embodiments, the first cutting assembly may be located prior to the second cutting assembly along the length of the conveyor.

[0014] Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of inventions disclosed.Description of the Figures

[0015] The accompanying drawings facilitate an understanding of the various embodiments. The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

[0016] Figure 1 is a schematic diagram of an apparatus for removing a flesh portion from a poultry carcass in accordance with one embodiment.

[0017] Figure 2a is a side view of an embodiment of a poultry carcass attachment on a plate unit.

[0018] Figure 2b is a close up perspective front view of an embodiment of a leg holder of the poultry carcass attachment.

[0019] Figure 3 is a side view of the embodiment of a poultry carcass attachment of Figure 2a having a poultry carcass mounted thereon in use.

[0020] Figure 4a is a perspective top view of an embodiment of a first cutting implement of a first cutting assembly.

[0021] Figure 4b is a perspective view from below of an embodiment of the first cutting implement of Figure 4a, including a pair of wishbone guides.

[0022] Figure 5a is a perspective view from below of an embodiment of a second cutting implement of the first cutting assembly.

[0023] Figure 5b is a perspective side view from above of an embodiment of skin removal hooks of the first cutting assembly.

[0024] Figure 6a is perspective side view of an embodiment of a first pair of knives of the preparatory cutting assembly of the second cutting assembly.

[0025] Figure 6b is a perspective view from above of an embodiment of a pair of skids of the preparatory cutting assembly of the second cutting assembly.

[0026] Figures 6c and 6d are a perspective side view and a rearward facing perspective view, respectively, of an embodiment of a second pair of knives of thepreparatory cutting assembly of the second cutting assembly.

[0027] Figure 6e is perspective side view of an embodiment of a pair of upright knives of the preparatory cutting assembly of the second cutting assembly.

[0028] Figure 7a is perspective forward facing view of an embodiment of the primary cutting assembly of the second cutting assembly.

[0029] Figures 7b and 7c are a close-up rearward facing view and a close up side perspective view, respectively, of an embodiment of the cutting implements of the second cutting assembly.

[0030] Figures 7d and 7e are a close-up forward facing perspective view and a close up front perspective view, respectively, of an embodiment of the horizontal and vertical augers of the second cutting assembly.

[0031] Figure 8 is a side view of the embodiment of a poultry carcass attachment of Figure 2a having a skeletal frame mounted thereon following completion of use of the apparatus.

[0032] Figure 9 is perspective forward facing view of an embodiment of a pair of rotary knives provided in a further embodiment of the preparatory cutting assembly of the second cutting assembly.

[0033] Figure 10 is a forward facing perspective view of a further embodiment of the cutting implements of the second cutting assembly.

[0034] Figure 11 is a perspective view of yet a further embodiment of the cutting implements of the second cutting assembly, prior to installation on the assembly.Detailed Description

[0035] Referring to the figures there is show an embodiment of an apparatus 100 for removing flesh portion from a poultry carcass 90. Where like reference numerals are used in the following description, the features are considered to be the same unless specified as being otherwise.

[0036] As used herein the term "poultry" refers to domesticated fowl collectively, and in particular those valued for their meat and eggs, such as for example chickens, turkeys ducks, geese, and guinea fowl. As used herein the term "poultry carcass" refers to the body of a slaughtered domestic foul after removal of the feathers and at least some of the innards not recommended for human consumption. As used herein the term "breast flesh portion" refers to the two halves of a poultry breast, typically taken from the pectoral muscle on the underside of the poultry. As used herein the term "leg flesh portion" refers to the whole leg of the poultry, including both the drumstick and thigh.

[0037] Referring to figure 1 there is shown a schematic diagram of the apparatus 100, which includes a platform 8 with legs of a given height for supporting a conveyor 1 above floor level. The conveyor 1 is in the form of an endless belt that is at least movable in a forward direction, which in figure 1 would be represented by a clockwise movement along the length of the platform 8 with the endless belt returning on the underside of the platform 8 directly facing towards floor level. As would be understood by one skilled in the art, the conveyor 1 can also be moveable in a reverse direction, i.e. anti-clockwise movement along the length of the platform 8.

[0038] Referring to figures 2a and 2b, the conveyor 1 has coupled thereto a poultry carcass attachment 25 which is able to support a poultry carcass 90 such that the poultry carcass 90 moves along the platform of the apparatus with movement of the conveyor 1. In some forms, the poultry carcass 90 can be dewinged prior to mounting on the poultry carcass attachment 25. The poultry carcass attachment 25 includes a saddle 5, which is inserted into the orifice of the poultry carcass 90, and is supported above the conveyor 1 by a supporting post 10 which extends substantially perpendicularly away from the conveyor 1. The supporting post 10 can be mounted to an outer face of a plate unit 20, with the inner face being coupled to the conveyor 1. For example, each plate unit 20 can be up to 500mm in length. The poultry carcass attachment assembly 25 being coupled to the conveyor 1 means that a poultry carcass 90 is able to be moved along the length of the platform 8 with a forward movement of the conveyor 1. The conveyor 1 is driven to move as a substantially constant speed of movement as it cycles along the platform. In some variations, the speed of movement of the endless belt of the conveyor 1 can vary during a single cycle, depending on the relative position of a poultry carcass attachment 25 along the platform.

[0039] The upper surface 11 of the saddle 5 extends longitudinally in a direction that is substantially parallel to the path of travel Y-Y of the conveyor 1. The saddle 5 is substantially centrally aligned above the conveyor 1 such that the poultry carcass 90 is supported to present substantially symmetrically on either side of the plane through which the path of travel Y-Y of the conveyor 1 passes. A hook 12 is located at a first end of the poultry carcass attachment 25, the hook 12 being adapted to project upwards and above the upper surface 11 of the saddle 5 so as to engage with the breast bone inside the orifice of the poultry carcass 90. A divider plate 13 extends downwardly from upper surface 11 of the saddle 5 towards the outer face of a plate unit 20. The divider plate 13 is adapted so as to locate inside the orifice of the poultry carcass 90 between the ribs and provide a rigid vertically extending support to the poultry carcass 90 from therein as it passes along the apparatus 100. A divider brace 13' extends below the divider plate 13 and is adapted to provide additional support for the legs 92 as the poultry carcass 90 passes along the apparatus 100. For example, the divider brace 13' can provide additional support for the legs 92 in the second cutting assembly 50 when the legs are being cut by the water knives.

[0040] A leg holder 6 is located at an opposing second end of the poultry carcass attachment 25, such that a lower portion of the legs 92 of the poultry carcass 90 are each secured by a respective notch 14 of a leg holder 6 on either side of the saddle 5. The leg holder 6 is fixed perpendicularly across the supporting post 10 at a height that is lower than the height of the upper surface 11 of the saddle 5, relative to the outer face of a plate unit 20. The leg holder 6 extends substantially laterally across the plate unit 20, and perpendicularly to the saddle 5. A U-shaped notch 14 is provided along the upper edge of the leg holder 6 on either side of the supporting post 10, such that a leg 92 of the poultry carcass 90 can be inserted within the notch 14 from above. The width of the notch 14 is less than a width of the end of an average sized tibia bone of a poultry carcass 90, thereby ensuring that the legs 92 remain securely held in the notches of the leg holder 6 on either side of the saddle 5.

[0041] The distance between the hook 12 and the leg holder 6 can be adjusted to ensure that the legs of the poultry carcass are held taught. For example, where the leg holder 6 is mounted to the supporting post 10 forward of the saddle 5, the saddle 5 and hook 12 can be biased away from the leg holder 6 by one or more spring 16 that is located between the supporting post 10 and the forward portion of the saddle 5. The spring 16 can be compressedor released to adjust the horizontal distance between the hook 12 and the leg holder 6.

[0042] Referring to figure 3, in use, the breast flesh portion 94 of the poultry carcass 90 locates substantially equally and symmetrically on either side of the saddle 5, with the breast bone of the poultry carcass 90 engaged by the hook 12 that locates on a rearward side of the saddle 5. Each tibia bone of the poultry carcass 90 is engaged by a respective notch 14 of a leg holder 6 that locates forward of the saddle 5. Thus, the poultry carcass 90 is held substantially taught by the poultry carcass attachment 25. When a poultry carcass 90 is mounted on the poultry carcass attachment 25, the breast flesh portion 94 of the poultry carcass 90 is orientated such that it faces away from the surface of the conveyor 1 in an upwards direction from the plate unit 20 and outwards away from the longitudinal centreline of the saddle 5.

[0043] Although the figures and description describe an apparatus comprising a singular poultry carcass attachment 25, in some variations the apparatus 100 can be configured for use with a plurality of poultry carcasses 90 of a substantially similar size and weight consecutively and in quick succession, with each poultry carcass 90 being mounted individually on a respective one of a plurality of poultry carcass attachment 25. Alternatively, in some variations, a plurality of poultry carcasses 90 of a varying size and weight can be each be mounted individually on a respective one of a plurality of poultry carcass attachments 25 and carried consecutively along the platform 8 by the conveyor 1 in quick succession, with the knives of the first cutting assembly 2 and second cutting assembly 50 responsively adapting and adjusting in width and / or height to accommodate for variations in poultry carcass 90 size and / or weight. For example, the knives of the first cutting assembly 2 and second cutting assembly 50 can be elastically biased using one or more springs to be able to responsively expand or contract in width corresponding to the contour of the ribs and / or thigh bones of the poultry carcass. In embodiments comprising a plurality of poultry carcass attachments 25, each poultry carcass attachment 25 can be mounted to an individual plate unit 20, with each plate unit 20 being spaced along the conveyor 1. For example, the spacing between consecutive plate units 20 can be substantially equidistant. For example, in some variation the spacing between consecutive plate units 20 can be between 50mm and 100mm. In some embodiments having a plurality of poultry carcass attachments 25, the apparatus 100 may advantageously be capable of processing between 600 and 1200 poultrycarcasses 90 per hour.

[0044] Referring now to figure 4a and 4b, the apparatus 100 also includes a first cutting assembly 2 which includes a first cutting implement such as an air knife or mechanical knife which is adapted to part and cut the breast flesh portion 94 of the poultry carcass 90 adjacent the wishbone, as the poultry carcass 90 is carried by the poultry carcass attachment 25 to move along the conveyor 1 in the forward direction beneath the first cutting implement. The first cutting implement can be a set of dual rotary discs 22 with sharpened outer circumferences. Each of the dual rotary discs 22 have the same outer diameter, and are supported to rotate about a concentric axis A-A that is aligned centrally above the conveyor 1. The dual rotary discs 22 are positioned to rotate at a height above the poultry carcass attachment 25 and conveyor 1, whereby the first cutting implement is able to open up the top of the breast flesh portion 94 of the poultry carcass 90 adjacent the wishbone, without cutting the poultry carcass 90 in half, and without engaging with the saddle 5. The axis A-A extends substantially perpendicularly across the path of travel Y-Y of the conveyor 1, with a planar surface of each of the rotary discs 22 extending parallel to the path of travel Y-Y of the conveyor 1. The dual rotary discs 22 can be spaced between 4mm and 5mm apart from one another, substantially symmetrically across the path of travel Y-Y of the conveyor 1.

[0045] A pair of guide plates 28 locate forward of the first cutting implement and extend along the length of the first cutting assembly 2 on either side of the conveyor 1, and substantially parallel to the path of travel Y-Y of the conveyor 1. Each of the guide plates 28 are spaced away from the poultry carcass attachment 25 by a distance that corresponds to slightly less than an average thickness of a breast flesh portion 94, whereby in use the guide plates 28 are able to apply a gentle compressive force on the breast flesh portion 94 of the poultry carcass 90 supported by the poultry carcass attachment 25 from either side. The guide plates 28 help to centre the poultry carcass 90 on the poultry carcass attachment 25 prior to engagement with the first cutting implement, and help to maintain a substantially symmetrical and central position of the poultry carcass 90 on the poultry carcass attachment 25 whilst the poultry carcass attachment 25 moves through the first cutting assembly 2.

[0046] The first cutting assembly 2 also comprises a pair of wishbone guides 24 which locate proximal to the outwardly facing surfaces of each of the rotary discs 22. Thewishbone guides 24 follow a similar curvature to that of the circumference of the rotary discs 22, and are offset rearwardly of the leading edges of the rotary discs 22 such that the wishbone guides 24 engage the breast flesh portion 94 of the poultry carcass 90 after the dual rotary discs 22 have already started cutting and parting the breast flesh portion 94. The wishbone guides 24 then help to separate the flesh of the breast flesh portion 94 away from wishbone on either side of the poultry carcass 90, whereby the wishbone remains attached to the skeletal frame 95 of the poultry carcass 90.

[0047] Referring now to figures 5a and 5b, the first cutting assembly 2 also includes a second cutting implement which is adapted to cut and separate the majority of the remaining flesh of the breast flesh portion 94 off the skeletal frame 95 of the poultry carcass 90, as the poultry carcass 90 continues to move along the conveyor 1 in the forward direction after engagement of the first cutting implement. The second cutting implement comprises a pair of knives 26 that extend downwardly from above the conveyor 1 towards, but stopping above, the height of the thigh of the poultry carcass 90 when the poultry carcass 90 is mounted on the poultry carcass attachment 25. A planar surface of each of the knives 26 is curved to follow a contour of the poultry carcass 90 adjacent the breast flesh portion 94, such that a leading edge of each knife 26 engages close to the skeletal frame 95 of the poultry carcass 90. For example, each knife 26 is shaped to curve outwardly from a substantially central position above the path of travel Y-Y of the conveyor 1 before curving downwardly towards the conveyor 1.

[0048] The first cutting assembly 2 also includes a pair of skin removal hooks 29 that extend inwardly from either side of the apparatus 100 towards the second cutting implement, with a leading edge of each hook being disposed to locate in-line with, and behind, the trailing edge of each of the knives 26 of the second cutting implement so as to remove the skin from the breast flesh portion 94 of the poultry carcass 90 after the breast flesh portion 94 has been cut and separated away from the skeletal frame 95 of the poultry carcass 90. Once the breast flesh portion 94 has been cut and separated away from the skeletal frame 95, the breast flesh portion 94 is allowed to fall to the platform 8 or via a chute, not shown, into a collection area.

[0049] Following separation of the breast flesh portion 94 by the first cuttingassembly 2, the poultry carcass attachment 25 is configured to be moved further along the platform 8 of the apparatus 100 by the conveyor 1 and enter a second cutting assembly 50 of the apparatus 100. The second cutting assembly 50 is configured to cut and separate the leg flesh portion 93 from the skeletal frame 95 of the poultry carcass 90.

[0050] Referring to figures 6a to 6e, the second cutting assembly 50 includes a preparatory cutting assembly 3 comprising a series of cutting implements 32,36,40 that are configured to make a series of preparatory incisions in and around the leg flesh portion 93 in order to enable the cutting implement / s of the primary cutting assembly 4 of the second cutting assembly 50 to remove the leg flesh portion 93 from the skeletal frame 95 of the poultry carcass 90.

[0051] Referring to figure 6a, as a first step, as the poultry carcass attachment 25 moves the poultry carcass 90 into the preparatory cutting assembly 3 a first pair of spring- loaded knives 30 are arranged to engage with an upper surface of each leg flesh portion 93 so as to slice an elongate incision along the upper surface of the leg flesh portion 93 thereby opening the flesh of the leg flesh portion 93 and exposing the sinews along the bones of the leg 92 between the ankle 96 and hip 97 of the poultry. The first pair of knives 30 are pivotable about a rod 31 that extends perpendicularly across the path of travel Y-Y of the conveyor 1, and elastically biased using one or more springs 32 so as to be urged rearwards against the path of travel Y-Y of the conveyor 1 and downwards towards the platform 8. The bias of the spring-loaded 32 mechanism is sufficient such that the first pair of knives 30 are able to apply a force against the leg flesh portion 93 as the poultry carcass 90 is moved past the first pair of knives 30 by the conveyor 1. Because the position of the first pair of knives 30 is fixed relative to the movement of the conveyor 1 in the forward direction, the first pair of knives 30, when engaged by the flesh of the poultry carcass 90, are biased by the springs 32 to provide a force against the leg flesh portion 93 in the opposite direction to the forward direction of the moving conveyor 1. The first pair of knives 30 are spaced apart from one another by a width that substantially corresponds to a width between the central points of the plurality of U-shaped notches 14 of the leg holder 6, whereby each of the first pair of knives 30 are able to align over the bones of a respective one of the legs 92 on a respective side of the poultry carcass 90 in use. In a variation, referring to Figure 9, a pair of rotary knives 33 can be used as an alternative to the first pair of knives 30 to engage with an upper surface of each leg flesh portion 93 so as to slice an elongate incision along the upper surfaceof the leg flesh portion 93 thereby opening the flesh of the leg flesh portion 93 and exposing the sinews along the bones of the leg 92 between the ankle 96 and hip 97 of the poultry.

[0052] Referring to figure 6b, following the incisions by the first pair of knives 30, the knees of the poultry carcass 90 are rolled out using a pair of skids 34 such that the leg flesh portion 93 extends substantially linearly between the ankles 96 and hips 97 of the poultry carcass 90.

[0053] Referring to figures 6c and 6d, after the leg flesh portion 93 have been extended out by the skids 34, the incisions opened by the first pair of knives 30 are engaged by a second pair of knives 36. The second pair of knives 36 are again spaced apart from one another on either side of the poultry carcass 90 and substantially aligned behind the skids 34 and first pair of knives 30. Each knife of the second pair of knives 36 has a curved lower edges 35 that is adapted to hook inside a respective incision and cradle around the leg bone. Each of the curved lower edges 35 projects outwardly away from a centreline between the second pair of knives 36, the centreline being substantially collinear with the path of travel Y-Y of the conveyor 1. The second pair of knives 36 are pivotable about a joint 37 that extends parallel with the path of travel Y-Y of the conveyor 1, and elastically biased using one or more springs 38 so as to bias inwardly towards the centreline and upwards away from the platform 8. In use, as the poultry carcass 90 is moved in a forward direction, the second pair of knives 36 remain stationary relative to the conveyor 1, and are thus effectively dragged along the leg bone inside the leg flesh portion 93 in order to sever the sinews around the leg bone. The bias of the spring-loaded 37 second pair of knives 36 is sufficient such that the second pair of knives 30 are able to apply an outward force (i.e. away from the centreline) against the leg bone in order to remain engaged thereat as the poultry carcass 90 is moved past the second pair of knives 36 by the conveyor 1. The second pair of knives 36 are thus able to cut substantially all of, or at least a majority of, the sinews connecting the leg bones to the flesh of the leg flesh portion 93 between the ankles 96 and hips 97 of the poultry carcass 90, and in particular the sinews that connect to the knee of the poultry carcass 90. In some variations, one the hips 97 of the leg flesh portion 93 have passed the second pair of knives 36, a cam mechanism can be configured to retract the second pair of knives 36 by pivoting them in opposition to the direction of the bias of the springs 37, thereby unhooking the second pair of knives 36 from around the leg bones.

[0054] Referring to figure 6e, a final step of the preparatory cutting assembly 3 comprises a further pair of cutting implements, for example upright knives 40, that are configured to slice an incision beneath the hips 97 of the poultry carcass 90 between the leg flesh portion 93 and the breast flesh portion 94. The upright knives 40 are spaced at a width that is slightly less than that of the second pair of knives 36, so as to align with a respective one of the hip joints of the poultry carcass 90. The leading edge 41 of each of the upright knives 40 faces rearwardly of the apparatus 100 (i.e. counter to the forward direction of travel of the poultry carcass attachment 25 along the conveyor 1). The upright knives 40 are configured to rotate about an axis B-B that extends perpendicularly across the path of travel Y-Y. As the poultry carcass 90 passes by the upright knives 40, the upright knives 40 are pivoted to rotate towards the forward direction, with the leading edge slicing and cutting around the hips 97. The upright knives 40 are biased by a set of springs to elastically return to a substantially vertical upright orientation after the poultry carcass 90 has passed and disengaged therefrom as it continues to travel in the forward direction along the conveyor 1. The upright knives 40 can cut from adjacent the tail bone up to the hip bone 97 off the poultry carcass 90, before elastically snapping back to an upright configuration upon release from the poultry carcass 90.

[0055] Referring to figures 7a to 7e, the second cutting assembly 50 further includes a primary cutting assembly 4 which provides a cutting action for separating all, or at least a majority, of the flesh of the leg flesh portion 93 from the skeletal frame 95 of the poultry carcass 90. The poultry carcass attachment 25 moves the poultry carcass 90 towards the primary cutting assembly 4, so as to engage therewith, once the poultry carcass 90 has completely passed through the preparatory cutting assembly 3.

[0056] Referring to figures 7a, 7b and 7c, the primary cutting assembly 4 includes a pair of substantially horizontally extending augers 42 arranged on either side of the conveyor 1. The augers 42 are configured to pivot apart from one another (i.e. in a clockwise or counter-clockwise direction, respectively) relative to a resting position that is substantially parallel with the horizontal. The augers 42 of each pair of augers 42 are biased towards one another and the resting position, for example by one or more springs, not shown. Each pair of augers 42 projects inwardly towards the conveyor 1, and perpendicularly relative to thepath of travel Y-Y of the conveyor 1, and beyond the bones of the leg flesh portion 93, whereby in use the forward movement of the leg flesh portion / s 93 on either side of the poultry carcass 90 by the conveyor 1 provides sufficient force against the bias of the augers 42 so as to urge the upper 42 and lower 42' augers to separate enough to allow a respective one of the leg flesh portions 93 on one side of the poultry carcass 90 to enter and pass therebetween. The upper 42 and lower 42' augers are able to pivot up and / or down in a clockwise or counter-clockwise direction in order to closely follow the contours of the profile of the bone of the leg flesh portion 93 as it passes between the augers 42. The augers 42 act to pull on the flesh of the leg flesh portion 93 such that the flesh is under a tension force away from the bone of the leg 92. The tension force applied by augers 42, whilst not sufficient to cut the flesh from the bone, may help to present the flesh of the leg flesh portion for the subsequently engaged cutting implements 44,46. For example, where the primary cutting assembly 4 comprises water knives 46, holding the flesh taut may advantageously prevent the water knives 46 from damaging the flesh.

[0057] The primary cutting assembly 4 further includes a pair of rotary knives 44, with one rotary knife 44 of the pair located on either side of the conveyor 1. A planar surface of the disc-like rotary knives 44 extends vertically and perpendicularly relative to the path of travel Y - Y of the conveyor 1. The rotary knives 44 are configured to be retractable, yet biased towards one another and the conveyor 1, for example by one or more springs, not shown. In use, the forward movement of the leg flesh portion / s 93 on either side of the poultry carcass 90 by the conveyor 1 provides sufficient force against the bias of the rotary knives 44 so as to urge the rotary knives 44 outwardly away from the centrally located conveyor 1 in order to closely follow the contours of the profile of the bone of the leg flesh portion 93 as it passes alongside the rotary knives 44, thereby cutting the remaining sinews free from the bone of the leg flesh portion 93.

[0058] The primary cutting assembly 4 further includes a plurality of water knives 46 located on opposite sides of the platform 8, and facing inwardly towards the conveyor 1. The location of the water knives 46 is fixed relative to the moving conveyor 1, forward of the rotary knives 44, the horizontal augers 42 and vertical augers 52. The water knives 46 are each able to pivot and oscillate between a predetermined angular range about a respective supporting rod 47, with a centre of the angular range corresponding with the angle betweenthe rod 47 and the leg holder 6. For example, the angular range may be between 45 and 90 degrees. For example, the primary cutting assembly 4 can comprise four water knives 46, with one water knife located above the height of the leg holder 6 and to the left of the conveyor 1, one water knife located above the height of the leg holder 6 and to the right of the conveyor 1, one water knife located below the height of the leg holder 6 and to the left of the conveyor 1, and one water knife located below the height of the leg holder 6 and to the right of the conveyor 1 in the forward direction. Each of the four water knives 46 can be configured to pivot through a predetermined range of XX degrees in order to cut the flesh of the leg flesh portion 93 in regions of the leg flesh portion 93 not accessible by the rotary knives 44 or the preparatory cutting assembly 3. The water knives may operate at a pressure of between about 3000 psi to about 20000 psi, and in some forms preferably 5000 psi, and about 5Lpm to about 20Lpm each other moving in upwards and downwards direction at about 30 to about 120 revolutions per minute. The oscillating water knives 46 may thus be able to cut the remaining connections between the flesh and the bone of the leg flesh portion 93.

[0059] In some variations, the primary cutting assembly 4' can comprise one (e.g. Fig. 10) or a plurality (e.g. Fig. 11) of rotary blades 43 that are positioned forward of the rotary knives 44, the horizontal augers 42 and vertical augers 52. The rotary blades 43 can have a smaller diameter circular shape relative to the larger disc-like rotary knives 44. In embodiments comprising a singular rotary blade 43, the rotary blade 43 can be positioned and aligned substantially centrally above the conveyor 1 forward of the rotary knives 44, and at a height such that the blade is able to part the flesh off the bone in a region of the leg flesh portion 93 not accessible by the rotary knives 44 or the preparatory cutting assembly 3. In embodiments comprising a plurality of rotary blades 43', for example two blades, the rotary blades 43' can be aligned substantially centrally above the conveyor 1 forward of the rotary knives 44, with one blade 43' positioned at a height above the leg flesh portion 93 and the other blade 43' positioned at a height below the leg flesh portion 93 so as to assist with parting the flesh off the leg bone from above and below the leg flesh portion 93 in regions of the leg flesh portion 93 not accessible by the rotary knives 44 or the preparatory cutting assembly 3.

[0060] Referring to figures 7d and 7e, the primary cutting assembly 4 comprises a plurality of elongate vertical augers 52 that are arranged to extend substantially verticallybetween the platform 8 and an upper support beam 53 that locates at a height above the hip 97 of the poultry carcass 90. Each vertical auger 52 is driven to rotate about a respective vertical axis. Each vertical auger 52 comprises a plurality of paddles that project away from a central body of each auger, with a length of each paddle being substantially equidistant above the central body. For example, a vertical auger 52 can comprise five paddles 54 that are each spaced equidistantly about the central body 55, with each paddle 54 extending for a substantially equal distance away from the central body 55. As would be appreciated by a person skilled in the art, the number of augers and paddles per auger can vary provided the arrangement of the augers is able to grip and remove the flesh of the leg flesh portion 93 away from the cutting implements 44,46 of the primary cutting assembly 4 by pulling the flesh to a respective side (i.e. away from the conveyor 1). The augers 52 can be formed from a material such as metal or rubber.

[0061] For example, a set of three augers 52 can be arranged on either side of the conveyor in front of (i.e. rearward of the direction of travel) of the cutting implements 44,46 of the primary cutting assembly 4. A first and second auger 52,52' are located adjacent to the conveyor 1, at a close distance to one another. The first and second auger 52,52' can be close enough whereby a circular circumference around each of the first and second augers 52,52' can overlap. A plane drawn between the respective axis of the first and second augers 52,52' extends parallel to the linear path of travel Y-Y of the conveyor. In use, the augers 52 engage with the respective flesh portion of the poultry carcass 90 as the poultry carcass 90 is moved along the length of the conveyor 1 in the forward direction. As the poultry carcass 90 is moved in the forward direction by the poultry carcass attachment 25, the cut and separated leg flesh portion 93 is pulled away to a respective side of the conveyor 1 by the augers 52, and in the opposite direction to the movement of the conveyor 1 and the remainder of the skeletal frame 95 and poultry carcass 90. The first and second auger 52,52' are located close enough alongside the conveyor 1 such that they interact with the flesh of the leg flesh portion 93, effectively gripping, clamping and / or pulling the flesh of the leg flesh portion 93 therebetween after the flesh of the leg flesh portion 93 has been cut and separated from the skeletal frame 95 of the poultry carcass 90 by the cutting implements 44,46 of the primary cutting assembly 4. A third vertical auger 52" is configured to hang from the beam 53 down to a free opposing distal end, and positioned such that the axis about which the third vertical auger 52" rotates is substantially halfway between the axis of the first and second augers52,52', but offset from the first and second augers 52,52' such that the third vertical auger 52" is spaced at a greater distance away from the conveyor 1 than the first and second auger 52,52'. The third vertical auger 52" may help remove the flesh of the leg flesh portion 93 from the first and second augers 52,52', and may reduce the likelihood of flesh become trapped or stuck to the first and second augers 52,52'.

[0062] The combination of the pulling force of the augers 52 that engage the flesh of the leg flesh portion 93 of the poultry carcass 90 and the cutting action of the primary cutting assembly 4 provides that the flesh of the leg flesh portion 93 is pulled from the remainder of the poultry carcass 90 as the poultry carcass 90 is moved past the primary cutting assembly 4 on the poultry carcass attachment 25 by the movement of the conveyor 1 in the forward direction. Once the leg flesh portion 93 is pulled from the remainder of the poultry carcass 90, the leg flesh portion 93 falls onto the conveyor 1 or to the side of the platform 8 and the remainder of the poultry carcass 90 continues along the conveyor and will drop off the end of the platform 8 once the poultry carcass attachment 25 assembly reaches this point.

[0063] In use, the poultry carcass attachment 25 is moved by the conveyor 1 in forward direction along the platform 8 in a substantially linear path of travel Y-Y. The poultry carcass attachment 25 is first moved through the first cutting assembly 2, where the breast flesh portion 94 is removed from the skeletal frame 95 of the poultry carcass 90. The poultry carcass attachment 25 is then moved through the second cutting assembly 50, where the leg flesh portion 93 is removed from the skeletal frame 95 of the poultry carcass 90. A significant advantage which is provided by the method and apparatus described is that the breast flesh portion 94 as well as the leg flesh portion 93 of the poultry carcass 90 is removed in one piece without significant flesh being left behind on the skeletal; frame 95 of the poultry carcass 90. This provides an efficient and significantly automated process for removing the flesh portion from the poultry carcass during processing.

[0064] Advantageously, the apparatus 100 can process both the breast flesh portion 94 and leg flesh portion 93 consecutively, without requiring a separate apparatus in order to process each flesh portion. The singular apparatus 100 thus provides an all-in-one capability for cutting and separating both the breast flesh portion 94 and leg flesh portion 93 from the skeletal frame 95 of the poultry carcass 90, which may advantageously improve theefficiency of the removal of the flesh from a poultry carcass 90. For example, the apparatus 100 may reduce the processing time per poultry carcass 90. In a further example, the apparatus can improve the consistency and / or quality of the cut breast flesh portion 94 and / or leg flesh portion 93. As would be appreciated by one skilled in the art, in a variation the apparatus 1 can be assembled to comprise only one of the first cutting assembly 2 or the second cutting assembly 50, with the modified apparatus being capable of repeatedly producing one of the breast flesh portion 94 or leg flesh portion 93 cuts on a large scale.

[0065] Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure.

[0066] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "front" and "rear", "inner" and "outer", "above", "below", "upper" and "lower" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0067] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0068] In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of’. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0069] In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and / or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodimentsbeing illustrative and not restrictive.

[0070] Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims

CLAIMS:

1. An apparatus for removing a flesh portion from a poultry carcass, the apparatus comprising an elongate platform having a conveyor that is movable along a length of the platform, the conveyor comprising one or more poultry carcass attachments adapted for coupling the conveyor to the poultry carcass such that the poultry carcass is orientated with a breast flesh portion of the poultry carcass facing away from an upper surface of the platform, wherein the apparatus further comprises at least one of a first cutting assembly configured to remove a breast flesh portion of the poultry carcass, and / or a second cutting assembly configured to remove a leg flesh portion of the poultry carcass, and wherein the first cutting assembly and / or the second cutting assembly are arranged on the upper surface of the platform adjacent the conveyor whereby movement of the conveyor in a forward direction enables the first cutting assembly and / or the second cutting assembly to remove the flesh portion of the breast and / or leg.

2. The apparatus of claim 1, wherein the poultry carcass attachment comprises a saddle that is insertable within an orifice of the poultry carcass and a leg holder adapted for securing the legs of the poultry carcass.

3. The apparatus of claim 2, wherein the poultry carcass attachment further comprises a hook adapted to project upwards and above an upper surface of the saddle, the hook being arranged on an opposing side of the saddle to the leg holder.

4. The apparatus of claim 3, wherein a distance between the hook and the leg holder can be adjusted.

5. The apparatus of any one of the preceding claims, wherein the poultry carcass attachment is arranged such that the poultry carcass is able to be supported substantially symmetrically on either side thereof.

6. The apparatus of any one of the preceding claims, wherein the apparatus comprising a plurality of poultry carcass attachments.

7. The apparatus of any one of the preceding claims, wherein the first cutting assembly comprises a first cutting implement adapted to cut the flesh portion adjacent a wishbone of the poultry carcass.

8. The apparatus of claim 7, wherein the first cutting implement is a pair of rotary disc knives.

9. The apparatus of any one of the claims 7 or 8, wherein the first cutting assembly further comprises a pair of wishbone guides that are offset rearwardly from a leading edge of the rotary disc knives and that are adapted for separating the breast flesh portion away from the wishbone.

10. The apparatus of any one of the claims 7 to 9, wherein the first cutting assembly further comprises a second cutting implement that is adapted to cut at least a majority of the remaining flesh of the breast flesh portion off the poultry carcass.

11. The apparatus of claim 10, wherein the second cutting implement is a pair of curved knives.

12. The apparatus of any one of the claims 10 or 11, wherein the first cutting assembly further comprises one or more skin removal hooks arranged to align behind a trailing edge of each of the pair of curved knives of the second cutting implement.

13. The apparatus of any one of the preceding claims, wherein the second cutting assembly comprises a preparatory cutting assembly configured to make a series of preparatory incisions in and / or around the leg flesh portion, and a primary cutting assembly configured to cut and remove the leg flesh portion from the poultry carcass.

14. The apparatus of claim 13, wherein the conveyor is adapted to move along the platform past the preparatory cutting assembly prior to the primary cutting assembly.

15. The apparatus of claim 14, wherein the preparatory cutting assembly comprises a plurality of cutting implements, each of the plurality of cutting implements being elastically biased towards a resting configuration by one or more springs, whereby in use each of the plurality of cutting implements is able to engage and cut the leg flesh portion whilst pivoting around a bone and / or joint of the leg flesh portion so as to allow the leg flesh portion to pass thereby.

16. The apparatus of claim 15, wherein at least one of the plurality of cutting implements of the preparatory cutting assembly is adapted to cut one or more of the sinews along between the flesh portion of the leg and a bone of the leg.

17. The apparatus of any one of claims 14 to 16, wherein the primary cutting assembly comprises one or more cutting implements adapted for cutting a remaining portion of the flesh of the leg flesh portion off the poultry carcass and one or more separation assemblies configured for removing the cut remaining portion of the flesh away from the one or more cutting implements.

18. The apparatus of claim 17, wherein the one or more separation assemblies are located in front of the one or more cutting implements of the primary cutting assembly as the conveyor moves the poultry carcass in the forward direction.

19. The apparatus of claims 17 or 18, wherein the one or more cutting implements of the primary cutting assembly comprise one or more of rotary knives and water knives.

20. The apparatus of claim 19, wherein at least one of the one or more cutting implements of the primary cutting assembly is a water knife.

21. The apparatus of claim 20, wherein the primary cutting assembly comprises a plurality of water knives, each water knife being configured to oscillate about an axis that extends substantially parallel to the forward direction of the conveyor, and each water knife being spaced from one another on either side of the conveyor.

22. The apparatus of any one of claims 19 to 21, wherein the water knife operates at a pressure between about 3000 psi to about 20000 psi.

23. The apparatus of any one of claims 17 to 22, wherein the primary cutting assembly further comprises a first set of augers adapted to grip and apply a tension force to the flesh of the leg flesh portion prior to engagement of the leg flesh portion with the one or more cutting implements of the primary cutting assembly.

24. The apparatus of any one of claims 17 to 23, wherein the one or more separation assemblies comprise a second set of augers adapted to grip and pull the remaining portion of the flesh away from the one or more cutting implements.

25. The apparatus of any one of the preceding claims, wherein the apparatus comprises both the first cutting assembly and the second cutting assembly.

26. The apparatus of claim 25, wherein the conveyor is adapted to move along the platform past the first cutting assembly prior to the second cutting assembly.

27. A method of removing a flesh portion from a poultry carcass, the method including: coupling a poultry carcass to a conveyor moving in a forward direction wherein the poultry carcass is orientated with a breast flesh portion of the poultry carcass facing away from a surface of the conveyor; and moving the poultry carcass through one or more cutting assemblies wherein each of the one or more cutting assemblies removes a respective flesh portion from the poultry carcass.

28. The method of claim 27, wherein the one or more cutting assemblies comprise at least one of a first cutting assembly configured to remove a breast flesh portion of the poultry carcass, and / or a second cutting assembly configured to remove a leg flesh portion of the poultry carcass.

29. The method according to claims 27 or 28, wherein the poultry carcass is de-winged prior to the coupling of the poultry carcass to the conveyor.

30. The method according to any one of claims 27 to 29, wherein the method is performed using an apparatus according to any one of claims 1 to 26.

31. An apparatus for removing a flesh portion from a poultry carcass, the apparatus including: a conveyor in the form of an endless belt and moveable in a forward direction, a poultry carcass attachment assembly fixed onto the conveyor, the poultry carcass attachment assembly adapted for attaching a poultry carcass to the conveyor whereby a breast flesh portion of the poultry carcass faces away from the surface of the conveyor when attached thereto, a first cutting assembly for cutting a breast flesh portion off the poultry carcass, and a second cutting assembly for cutting a leg flesh portion off the poultry carcass.

32. An apparatus according to claim 31 wherein the first cutting assembly is located prior to the second cutting assembly along the length of the conveyor.

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