Boneless Poultry Cut from Thigh via 45-Degree Segmentation

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Solution Overview

Problem

The poultry industry seeks cost-effective, boneless whole muscle poultry items that are as appealing and marketable as chicken tenders but less expensive, as boneless chicken breast and tenders are premium products with significant waste and higher costs.

Innovation Solution

A method of cutting the poultry thigh into a bone-in and boneless portion by creating a 45-degree cutline under the iliofibularis, separating the saddle into halves, and cutting the thigh portion at an angle to produce two lighter whole meat cuts similar to winglets, reducing waste and cost while maintaining texture and taste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chicken breast or tender meat is used as boneless poultry items, then the texture and taste of whole muscle items are maintained, but the cost increases significantly and waste is generated

Engineering Contradiction:

Improvetexture and taste qualityVSAvoidwaste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The poultry thigh is segmented into distinct portions through specific cutting lines (45-degree cutline, middle cutline) to create separate boneless and bone-in portions, allowing the boneless portion to be utilized as a valuable product while minimizing waste

Inventive Principle:

Principle #1Segmentation

2Reliability

If chicken breast or tender meat is used as boneless poultry items, then the texture and taste of whole muscle items are maintained, but the cost increases significantly

Engineering Contradiction:

Improvetexture and taste qualityVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Instead of using traditional premium cuts (breast, tender) for boneless products, the invention inverts the approach by using the thigh portion and creating boneless cuts from it, providing a cost-effective alternative that maintains whole muscle quality

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If the thigh is cut using traditional cutting methods, then the process is simple, but the resulting product does not provide a cost-effective alternative to premium boneless items

Engineering Contradiction:

Improvecutting process simplicityVSAvoidproduct value

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The cutting parameters are changed by introducing specific angles (45-degree cutline) and positions (middle cutline halfway between 45-degree cutline and inner edge) to transform the thigh into valuable boneless portions, increasing product value while maintaining manufacturing simplicity

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10561152B1Product cut from the thigh of a poultry item and a method of producing the same

Publication Date: 2020.02.18 TYSON FOODS INC

AI summary

An article of manufacture, namely a poultry cut food product, and a method of producing the article of manufacture. The article of manufacture includes a portion cut of the thigh of a poultry item or other bird.