Super-Chilled Poultry Carcass Airflow for Bacterial Kill Without Freezing
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Solution Overview
Problem
Current methods for disinfecting poultry carcasses are ineffective in eliminating bacterial contamination, particularly Campylobacter and Salmonella, due to restrictions on using disinfectants in potable water, and existing rapid chill processes do not reliably kill bacteria without freezing 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, while orienting the carcasses with the sternum 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 regulations prohibit this method in Europe
Solution Approach 1:
The patent uses super-chilled air as an intermediary substance to transfer thermal energy to the carcass surface, enabling bacterial killing without direct contact with prohibited chemical disinfectants. The air acts as a mediator that delivers the bactericidal effect through extreme cold rather than chemical action.
Solution Approach 2:
The invention changes the temperature parameter of air to extremely low levels (super-chilled conditions) to achieve a bactericidal effect. By transforming air from a neutral cooling medium to a super-chilled bactericidal agent, the process achieves disinfection without chemicals, resolving the contradiction between effectiveness and regulatory compliance.
2Duration of action of stationary object
If crust freezing is used to inhibit bacterial growth, then shelf life is improved, but the process does not reliably kill bacteria
Solution Approach 1:
The patent intensifies the temperature parameter beyond conventional crust freezing levels to super-chilled conditions, transforming the process from merely inhibiting bacterial growth to reliably killing bacteria. This parameter escalation achieves both extended shelf life and dependable bacterial elimination.
Solution Approach 2:
The process uses periodic alternation between super-chilled air exposure and tempering periods, allowing bacterial killing during the cold exposure phases while enabling meat quality recovery during tempering phases. This periodic action achieves reliable bacterial elimination without permanent damage to the meat.
3Reliability
If super-chilled air is used to kill bacteria, then bacterial viability is reduced, but meat quality may be damaged
Solution Approach 1:
The patent implements periodic cycles of super-chilled air exposure followed by tempering periods. During super-chilled exposure, bacteria are killed; during tempering, the meat recovers and stabilizes. This periodic action achieves reliable bacterial elimination while preventing cumulative damage to meat quality.
Solution Approach 2:
The tempering phase acts as a cushioning recovery period that prevents damage accumulation from repeated super-chilled exposures. By allowing the meat to gradually adjust and recover between treatment cycles, the process protects meat quality while maintaining bacterial killing effectiveness.
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 at least 99.9%, effectively killing bacteria while maintaining the quality and appearance of the meat, with minimal damage from the super-chilled air.
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
said flow is directed over said carcasses and into the body cavity of said carcasses
Implementation Method 3
This process significantly reduces the number of viable microorganisms on poultry carcasses by at least 99.9%, effectively killing bacteria
Data Source
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.