Rapid Poultry Carcass Chilling for Bacterial Reduction Without Freezing
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Solution Overview
Problem
Current methods for disinfecting poultry carcasses are ineffective in eliminating bacteria like Campylobacter and Salmonella without using chemical disinfectants, which are prohibited in Europe, and existing rapid chill processes do not reliably kill bacteria without damaging the meat.
Innovation Solution
Exposing poultry carcasses to a flow of gaseous air at temperatures between -50°C and -120°C for a short duration, directing the air over and into the body cavity with the sternum facing downstream, to achieve a bactericidal effect without freezing the meat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If poultry carcasses are washed with water containing disinfectants, then bacterial contamination is reduced, but chemical residues remain on the meat and disinfectants are prohibited in Europe
Solution Approach 1:
The invention changes the temperature parameter of the air flow to extremely low temperatures (-50°C to -120°C) to achieve bactericidal effects without chemical substances. This parameter change allows the process to eliminate bacteria while leaving no chemical residues on the meat, resolving the contradiction between effective decontamination and absence of harmful chemical factors
Solution Approach 2:
The invention replaces the chemical disinfection system with a physical cold air flow system. Instead of using chemical disinfectants washed over the carcasses, the patent uses controlled cold air flow at specific temperatures and durations to achieve bacterial elimination, substituting mechanical/physical action for chemical action
2Reliability
If crust freezing is applied to inhibit bacterial growth, then shelf life is improved, but the meat becomes frozen and quality deteriorates
Solution Approach 1:
The invention applies dynamic temperature control where the carcasses are exposed to cold air at -50°C to -120°C for a limited time (1-60 seconds), then removed and allowed to warm. This dynamic approach achieves bactericidal effects during the cold exposure while preventing permanent freezing and quality deterioration through controlled exposure time and subsequent warming
Solution Approach 2:
The process uses periodic action by exposing carcasses to cold air flows in cycles - exposure to bactericidal temperatures followed by removal and warming periods. This periodic application allows bacterial killing during cold phases while preventing permanent damage during warm phases, resolving the contradiction between bacterial inhibition and quality maintenance
3Reliability
If rapid chill processes use temperatures of -40°C to -120°C, then bacterial viability is reduced, but meat freezing occurs causing quality loss
Solution Approach 1:
The invention applies partial action by using excessive cold temperatures (-50°C to -120°C) for a limited portion of time (1-60 seconds) rather than prolonged exposure. This partial application achieves bactericidal effects through the intense cold while preventing complete freezing and quality loss by limiting the duration of exposure, thus resolving the contradiction between bacterial viability reduction and prevention of meat freezing
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 process significantly reduces the number of viable microorganisms on poultry carcasses by up to 99.9% without damaging the meat, maintaining its quality and natural state, and can be integrated into existing processing lines.
Implementation Method 1
exposing poultry carcasses to a flow of gaseous air at a temperature in the range from about -50°C to about -120°C
Implementation Method 2
WO 04/080 189 A discloses rapidly cooling meat by exposure to a rapid cooling temperature of no more than about -10°C for sufficient time to form a frozen crust on the meat
Data Source
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AI summary
Poultry carcasses are chilled rapidly when exposed to a flow of gaseous air at a temperature in the range from about -50°C to about -120°C for a period of time in the range from about 1 s to about 60 s. The flow is directed over and into the body cavity of the carcasses. The carcasses are orientated in the flow such that the sternum of each carcass faces downstream. One advantage of the process is that the number of viable microorganisms present on the carcasses is reduced significantly while avoiding freeze-damage to the carcasses.