Broiler Meat Shelf Life Extension via Ice Mud Cooling
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Solution Overview
Problem
Existing methods for refrigerated poultry meat storage result in a short shelf life of around 6-7 days due to bacterial growth, lacking precise criteria for cold storage and ineffective cooling processes, which leads to organoleptic changes and microbial contamination.
Innovation Solution
Implementing innovative cooling techniques using 'ice mud' and controlled refrigeration, combined with high-pressure washing and disinfection systems, along with measures to improve chicken welfare and reduce stress, to achieve rapid carcass cooling and maintain low storage temperatures, thereby reducing microbial growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional refrigeration storage is used, then energy consumption is reduced and simplicity is maintained, but shelf life is limited to 6-7 days due to bacterial growth
Solution Approach 1:
The cooling process is divided into multiple stages: pre-cooling of carcasses after slaughter, continued cooling during storage, and maintenance cooling during transport. Each stage uses appropriate cooling intensity and method suited to that phase, allowing extended shelf life without requiring one complex high-capacity cooling system throughout
Solution Approach 2:
Carcasses are pre-cooled immediately after slaughter and before storage to establish low initial temperatures. This preliminary cooling action reduces the microbial load and slows bacterial growth from the outset, extending the subsequent storage period without requiring intensive cooling throughout the entire storage duration
2Duration of action of moving object
If storage temperature is increased slightly, then energy consumption decreases, but shelf life reduces significantly due to exponential bacterial growth
Solution Approach 1:
Continuous monitoring and maintenance of storage temperature at or below 2°C ensures that the inhibitory effect on bacterial growth is constant throughout the storage period. This continuous temperature control prevents the exponential increase in bacterial growth that would occur with temperature fluctuations, maintaining shelf life without requiring excessive energy spikes
Solution Approach 2:
Temperature monitoring systems with feedback control adjust cooling operations to maintain temperatures within the optimal range (≤2°C). When temperature approaches the threshold, cooling is intensified; when well below, cooling is reduced. This feedback mechanism maintains shelf life extension while optimizing energy consumption by avoiding unnecessary over-cooling
3Reliability
If high-pressure washing and disinfection systems are implemented, then microbial contamination is reduced, but device complexity and initial investment increase
Solution Approach 1:
The high-pressure washing system is integrated into the existing slaughter and processing line, utilizing the same water supply and drainage infrastructure. The system uses the kinetic energy of high-pressure water jets to remove contaminants without requiring separate complex disinfection equipment, achieving enhanced meat safety through relatively simple modifications to existing infrastructure
Solution Approach 2:
The washing system operates at high pressure (increased pressure parameter) to achieve effective contaminant removal. This parameter change allows the use of water alone or with minimal chemical additives to achieve disinfection levels that would otherwise require complex multi-stage washing systems, improving meat safety without proportionally increasing device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method extends the shelf life of broiler chicken meat to 12 days without signs of organoleptic changes, maintaining a microbial count below 5×10^6 bacteria/g, ensuring meat quality and safety throughout the storage period.
Implementation Method 1
Cooling the carcass after plucking, before evisceration, using ice water
Implementation Method 2
stored under refrigeration
Data Source
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AI summary
The invention relates to a method for extending the shelf life of broiler chicken meat. A procedure to ensure the hygiene and quality of chicken meat through controlled cooling and reducing microbial growth, allowing meat to be stored for up to 12 days.