Poultry Foot Lesion Removal via High-Pressure Spray
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Solution Overview
Problem
Current methods for removing lesions from chicken feet are either labor-intensive, destructive, or partially effective, leading to a high number of poultry feet being graded as condemned or sub-grade, which reduces their commercial value.
Innovation Solution
A device and system that uses a conveyor and high-pressure spray heads to remove lesions from poultry feet within a poultry processing line, with adjustable pressure and flow rate to ensure effective lesion removal without damaging the feet, thereby improving grading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual removal of lesions is performed, then lesion removal can be achieved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical removal with an automated mechanical system consisting of a conveyor belt and spray heads. The conveyor automatically transports poultry feet through the cleaning zone, and spray heads deliver pressurized fluid to remove lesions, eliminating the need for manual labor while maintaining effective lesion removal.
Solution Approach 2:
The system enables self-service processing where the poultry feet are automatically conveyed and treated without human intervention. The conveyor and spray system work autonomously to remove lesions, reducing dependency on manual labor and increasing processing efficiency.
2Manufacturing precision
If brush-type or rubber finger contact systems are used to scrape lesions, then lesion removal can be achieved, but the paws are damaged and graded below A-grade
Solution Approach 1:
The patent uses pressurized fluid spray systems instead of mechanical contact methods. High-pressure nozzles deliver fluid to remove lesions without physical contact, eliminating the damaging scraping action of brushes or rubber fingers while effectively removing lesions from the paw surfaces.
Solution Approach 2:
The invention replaces direct mechanical contact removal methods with a fluid-based spray system. This substitution eliminates the harmful mechanical scraping forces that damage paw tissue while maintaining effective lesion removal through the action of pressurized fluid.
3Reliability
If chemical treatments are applied to prevent lesions, then some prevention can be achieved, but chemical safety issues and partial effectiveness remain
Solution Approach 1:
The system performs preliminary cleaning by removing lesions before grading occurs. By proactively eliminating lesions through spray treatment in the cleaning zone, the system prevents lesions from affecting the final grade, addressing the problem before it impacts product value.
Solution Approach 2:
The patent converts the potential harm of chemical treatments by replacing them with a physical spray method. The pressurized fluid system achieves lesion prevention and removal without introducing chemical safety concerns, turning a harmful approach into a safe and effective solution.
4Measurement precision
If sorting is performed manually by visual inspection, then grading can be done, but the process is time consuming and results in many paws being graded condemned or sub-grade
Solution Approach 1:
The patent replaces manual visual inspection with an automated spray treatment system that physically removes lesions. This mechanical substitution increases productivity by processing multiple feet simultaneously while maintaining grading accuracy through consistent lesion removal that ensures proper classification.
Solution Approach 2:
The conveyor system enables continuous processing of poultry feet through the cleaning zone, maintaining uninterrupted workflow. This continuous action increases productivity compared to discrete manual inspection while ensuring each paw receives consistent treatment for accurate grading.
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 efficiently removes lesions from poultry feet, enhancing their grading and commercial value by minimizing damage and increasing the number of feet classified as A-grade, thus reducing labor costs and improving processing efficiency.
Implementation Method 1
At least one spray head is located in the cleaning zone below the conveyor for spraying the poultry feet while held by the conveyor in the cleaning position to remove the lesion material, the spray head pressure being in the range of about 1600 to about 3200 pounds per square inch (psi)
Data Source
AI summary
Systems, methods, and devices are disclosed for removing lesion material from poultry feet. The systems, for example, can include at least one spray head located along a travel path of a plurality of movable shackles within a poultry processing line. Each shackle can be configured to hold a poultry member in a processing position as the shackles are moved along the processing line. The spray head configured to spray feet of the poultry members held by the plurality of shackles to remove the lesion material from the feet.