Dual Cascade Water Spray for Poultry Feather Removal
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Solution Overview
Problem
Current methods for removing feathers from poultry carcasses in large-scale processing involve submersion in heated water tanks, leading to microbial proliferation, pathogen contamination, and inefficiencies in processing capacity.
Innovation Solution
A method involving dual cascades of heated and chilled water to scald and cool poultry carcasses, combined with quill picking units to remove feathers, and a recirculation system to filter and reuse water, enhancing processing efficiency and reducing microbial contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If submersion scalding tanks are used to remove feathers from poultry carcasses, then feathers are effectively removed, but microbial and pathogen counts increase due to water contamination
Solution Approach 1:
The system divides the scalding process into multiple sequential spray zones rather than using a single submersion tank. Carcasses pass through a series of heated water spray applications, allowing effective feather removal while minimizing carcass exposure to contaminated water, thus reducing microbial transfer.
Solution Approach 2:
The invention extracts the harmful element (contaminated water) from the scalding process by replacing submersion in a shared water bath with individualized spray applications. Each carcass receives heated water independently, preventing cross-contamination between carcasses while maintaining effective feather removal.
2Productivity
If longer length submersion scalding tanks and more feather pickers are added to increase processing capacity, then more feathers are removed, but additional valuable floor space is consumed
Solution Approach 1:
The system transitions from static submersion tanks to a dynamic spray application system where heated water is applied sequentially as carcasses move through the line. This allows multiple scalding stages in a compact footprint, increasing processing capacity without proportionally increasing floor space requirements.
Solution Approach 2:
The invention utilizes the time dimension by applying heated water in sequential spray zones along the conveyor path, rather than requiring all scalding to occur simultaneously in a large tank. This transforms the process from a space-intensive batch operation to a time-sequenced continuous process, increasing capacity efficiency.
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
This method effectively removes feathers, reduces microbial and pathogen counts, and increases processing capacity without the need for additional space, thereby improving the efficiency and safety of poultry processing.
Implementation Method 1
scalding the poultry carcasses by passing the carcasses under a dual cascade of heated water
Implementation Method 2
the pores of the carcasses are relaxed and opened to facilitate removal of the feathers
Implementation Method 3
cooling the carcasses by passing the carcasses under a cascade of chilled water
Implementation Method 4
filtering the collected heated water for removal of particulate matter, and recirculating the filtered water
Data Source
AI summary
A system (20) for removing feathers from poultry carcasses (50), including a scalding apparatus (28) that applies the dual cascade of heated water downwardly onto poultry carcasses passing beneath. A quill picking unit (30) follows the dual cascade scalding apparatus (26) to remove the feathers from the carcass after the pores have been enlarged by the dual cascade of scalding water. After the feathers have been pulled from the carcass (50), the carcass is passed through a chiller (40) which applies a dual cascade of cooling water downwardly onto the carcasses passing through the chilling unit.