Small-Scale Poultry Processing

1. Objective
a. To document and maintain written procedures for small-scale poultry production.
2. Scope
a. These guidelines applies to the production of poultry meat from the reception of live
birds to storage of the finished product.
3. Definitions
4. Process flowchart
a. This diagram identifies the major components involved in poultry production.

Unit Processes [flowchart]

Dirty side

Killing and bleeding Feather Removal

Pre-slaughter Reception
[Scalding]

Shoe disinfection
Clean side

Inspection

Removal of Head, Oil

Glands, and Feet

Chilling Washing the Evisceration

Carcass
5. Poultry production [Part 1-Dirty side]
a. Pre-slaughter: Feed must be withheld for 12 hours before slaughter to limit the amount
of feed in the gut and the likelihood of tearing during processing that lead to faecal
contamination of the carcass. If the feed is withheld for too long this can lead to watery
Further Processing Packaging Storage
[Cut-up etc] intestines that may leak
b. Reception: Care must be taken during unloading and reception to prevent bruising and
broken bones.
c. Killing and bleeding:
i. Place birds in properly sized funnel shaped cones that are able to prevent the
bird from flapping its wings or backing out of the cone. This can lead to muscle
haemorrhaging and/or broken bones.
ii. Birds are killed by cutting the blood vessel on both sides of the neck. The
oesophagus should not be cut (this leads to contamination from leakage).
iii. DO NOT REMOVE THE HEAD AT THIS STAGE
 iv. Bleeding should take place for 1.5 to 3 minutes to allow for maximum drainage
and to prevent dark spots in the meat especially the wings.
d. Scalding and picking: To save time and labour birds should be placed in a basket (or
similar mechanism) to allow for the scalding of several birds together. To prevent the
scalding of birds in water that is too dirty it might be necessary to utilise two scalders
since it is difficult to maintain a time-temperature relationship when fresh water is
added. Scalding will not be allowed in water that is too dirty since this will undoubtedly
lead to increased microbial contamination of carcasses.
e. Transfer: carcasses are transferred from the dirty side to the clean side
6. Poultry production [Part 2 - Clean side]

a. Shoes disinfection:
b. Head, oil gland and feet removal
c. Evisceration: In general it is cleaner and easier to eviscerate on shackles. If the number
of birds being processed is minimal, evisceration will be permitted on a flat surface
(stainless steel or disposal plastic sheets).
i. Cut open the vent, open the body and draw out the organs.
ii. The guts must remain fully intact alongside the bird for inspection.
iii. If the gut is torn the carcass can be sprayed with a bottle of chlorinated water to
remove faecal matter. But, gross contamination will result in condemnation of
the entire carcass. [proper evisceration techniques are therefore
recommended].
iv. A torn crop can also be a major source of contamination.
7. Inspection: Carcasses will be inspected by an Environmental Health Officer immediately
following evisceration.
a. Inspection requires the following:
i. Adequate lighting
ii. hand washing station
iii. Bin for suspect or condemned birds.
iv. A mirror on the backside of the bird to allow the inspector to examine the
carcass.
b. The giblets are collected after inspection.
8. Final washing: Carcasses are thoroughly washed inside and out.
9. Chilling: The carcass temperature must be lowered to 4 oC by soaking in chilled water for at least
one hour.
a. The temperature should be taken in the breast of the carcass with a probe-type
thermometer.
b. Use food-grade plastic or stainless steel bins filled with cold water and ice to chill
carcasses.
c. Two tubs can be utilised in a series.
d. Place the carcass directly into this ice slush.
 10. Further processing: If carcasses are not sold whole, cutting and further processing will be
needed. In some cases because of bruising and broken bones carcasses will be cut-up.
a. Further processing also includes deboning, curing, smoking etc.
11. Packaging: After the carcass is properly chilled, it is ready to be packed.
a. The carcass must be aged for 4 hours after slaughter before freezing to minimise
toughness.
b. Packing must take place before the carcass before they warm up.
c. Birds are packed in clear plastic bags, closing it with a twist-tie.
12. Storage: Carcasses can be stored less than 4 oC in a refrigerator if they will be sold fresh or
frozen for long-term storage.