Multi-Bird Poultry Shackle Vertical Stacking
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Solution Overview
Problem
Conventional poultry chilling processes require extensive infrastructure and resources due to the need for multiple shackles and conveyor systems to handle individual birds, leading to high capital and operational expenses, as well as increased power requirements for sharp turn radii.
Innovation Solution
A multi-bird shackle design that allows for the simultaneous holding and conveyance of multiple birds using multiple tiers of leg loops on a single stanchion, significantly increasing the density of bird conveyance per linear foot of conveyor chain, with reduced turn radii and slower conveyor speeds to maintain efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-bird shackles are used, then each bird can be held and conveyed individually, but the conveyor requires large building space and extensive infrastructure
Solution Approach 1:
The patent combines multiple single-bird shackles into a single multi-bird shackle unit that can simultaneously hold and convey multiple birds (typically 6 birds) together. This merging of multiple individual handling units into one integrated structure increases the number of birds conveyed per conveyor location, thereby increasing productivity while reducing the total building space required for the conveyor system.
Solution Approach 2:
The multi-bird shackle utilizes vertical stacking to arrange multiple birds in different vertical levels (typically three levels with two birds per level). This dimensional arrangement allows multiple birds to occupy the same horizontal footprint area, effectively increasing conveyance capacity without proportionally increasing the building space required.
2Productivity
If conventional single-bird shackles are used, then each shackle can be simple in design, but the total infrastructure cost increases due to requiring more shackles and conveyor components
Solution Approach 1:
By merging multiple individual shackle units into a single multi-bird shackle, the system reduces the total number of separate conveyor components needed. Although each multi-bird shackle is more complex than a single-bird shackle, the overall infrastructure requires fewer Shackles, conveyor links, and support structures, thereby reducing total infrastructure cost while increasing birds per linear foot of conveyor.
3Productivity
If conventional systems use sharp turn radii to maximize bird density, then more birds can be fitted into given area, but power requirements increase to drive the chain and shackles around the system
Solution Approach 1:
The multi-bird shackle design allows for gentler, larger-radius turns while maintaining high bird density. Instead of requiring sharp turns to pack birds tightly, the vertical stacking configuration enables smoother conveyor paths with reduced curvature radius, thereby lowering the power requirements for driving the conveyor chain while still achieving high bird density through the multi-level arrangement.
Data Source
AI summary
A multi-bird poultry shackle includes a stanchion having a connection point adapted to couple to a conveyor; a first shackle coupled to the stanchion, the first shackle having a first pair of leg loops adapted to hold the legs of a first bird, and a second pair of leg loops adapted to hold the legs of a second bird; a second shackle coupled to the stanchion below the first shackle, the second shackle having a third pair of leg loops adapted to hold the legs of a third bird, and a fourth pair of leg loops adapted to hold the legs of a fourth bird; and a third shackle coupled to the stanchion below the second shackle, the third shackle having a fifth pair of leg loops adapted to hold the legs of a fifth bird, and a sixth pair of leg loops adapted to hold the legs of a sixth bird. A method of conveying poultry carcasses is also described.