Poultry Cleaning Spray System for Contamination Control
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Solution Overview
Problem
Commercial poultry processing facilities face significant challenges in reducing contamination and bacterial loads due to the accumulation of fecal matter and pathogens in scalding tanks, as current methods like revolving brushes are ineffective and can damage the birds, leading to increased foodborne illness risks.
Innovation Solution
A brushless high-pressure liquid spray system that uses pre-heated water at 130° F and pressures up to 650 psi, directed from top to bottom through a series of angled spray manifolds and nozzles to effectively clean poultry carcasses before scalding, dislodging and removing dirt and fecal material without damaging the skin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If revolving brushes are used to clean poultry carcasses, then cleaning action is applied, but the skin is damaged and pathogens are driven into tissues
Solution Approach 1:
The patent replaces the mechanical brush system with a high-pressure water spray system. Instead of using rotating brushes that physically contact and damage the skin, the invention uses pressurized water jets to remove contaminants. The spray system delivers water at pressures up to 650 psi, providing sufficient cleaning force without mechanical contact that would damage the skin or drive pathogens into tissues.
Solution Approach 2:
The patent employs hydraulic principles by using high-pressure water spray to clean the poultry carcasses. The system uses a water pump to generate pressurized water flow, which is then directed at the carcasses through spray nozzles. This hydraulic approach provides effective cleaning through fluid pressure rather than mechanical friction, eliminating the skin damage associated with brush systems.
2Productivity
If communal scalders are used to scald multiple birds, then processing efficiency is improved, but contamination and bacterial accumulation increase
Solution Approach 1:
The patent applies preliminary action by cleaning the poultry carcasses before they enter the scalding tank. The high-pressure water spray system removes dirt, fecal matter, and reduces bacterial loads on the carcasses prior to scalding. This preliminary cleaning prevents contaminants from accumulating in the scalding water, allowing the communal scalders to maintain higher processing efficiency without the same level of contamination that would require frequent water changes.
3Object-generated harmful factors
If frequent water replenishment is performed in scalding tanks, then contamination is reduced, but water consumption and operational cost increase
Solution Approach 1:
The preliminary cleaning action performed by the high-pressure water spray system before scalding prevents contaminants from entering and accumulating in the scalding tanks. By removing dirt and fecal matter on the carcasses prior to scalding, the system reduces the need for frequent water replenishment in the scalding tanks, thereby reducing overall water consumption while maintaining low contamination levels.
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 system significantly reduces contamination and bacterial loads, minimizes water consumption, and prevents re-contamination of scalding tanks, ensuring cleaner carcasses and a safer processing environment by using fresh water for each bird, thus reducing the need for frequent water replenishment and minimizing skin damage.
Implementation Method 1
A brushless high-pressure liquid spray system that uses pre-heated water at 130° F and pressures up to 650 psi, directed from top to bottom through a series of angled spray manifolds and nozzles to effectively clean poultry carcasses before scalding, dislodging and removing dirt and fecal material without damaging the skin.
Implementation Method 2
pre-heated water at 130° F
Data Source
AI summary
A poultry processing system having a cleaning station, a scalding station, a picker station and a transfer line for supporting a poultry carcass head down through the processing stations. The cleaning station including a plurality of spray manifolds coupled to a cleaning liquid supply each having a plurality of spaced apart spray nozzles for directing cleaning liquid onto the carcasses from the tail to head as they are transferred through the cleaning station for removing dirt, fecal material, and other foreign matter from the carcasses prior to transfer to the scalding and picker stations.