Technologies for processing poultry meat, eggs, and raw materials

Technological processes: processing of eggs and poultry meat

Deep processing of poultry and eggs allows farms to reduce losses, extend the shelf life of products, and expand sales channels. Table eggs are sold fresh or processed into dried and frozen products. Dried egg products (egg powder, dried albumen, and yolk) are characterized by high nutritional value, excellent solubility, and can be stored for a long time. They are produced both from whole eggs and separately.

To produce frozen egg mélange — a natural mixture of white and yolk or their individual fractions — specialized facilities are organized at enterprises. The technological chain must be strictly followed to prevent product contamination by microflora. The entire process consists of sequential steps that require strict sanitary discipline.

1. Receiving and sorting incoming eggs by weight.
2. Washing and disinfection of shells.
3. Breaking eggs.
4. Mixing the obtained egg mass and filtering it.
5. Pasteurization and subsequent cooling.
6. Portioning and packaging of the finished mass.
7. Freezing and sending the mélange for storage.

Poultry meat is delivered to the trade network in chilled, cooled, or frozen form. In addition to carcasses and offal (hearts, livers, gizzards, and necks), sausages, canned goods, and culinary products are made from poultry meat. Sausages are produced from meat of any poultry species: chickens, broilers, turkeys, geese, ducks, guinea fowl, and quail. Specialized machines are installed on lines for cutting carcasses into semi-finished products.

Feather and down raw materials and poultry waste utilization

Feathers and down are valuable raw materials obtained during the processing of poultry carcasses. They are used in the production of blankets, pillows, mattresses, sleeping bags, warm workwear, and decorative items. For plucking, intermittent-action machines equipped with a rotating drum with rubber fingers and plates are used. The yield of raw materials directly depends on the species and production purpose of the poultry.

The plucked wet feathers are first squeezed in a centrifuge and then sent for drying. The dried raw material is sucked by a fan from the feather dryer into a collector, after which it is packed into clean, dry containers.

• Initial feather humidity — 30–45%
• Drying temperature — 70 °C
• Drying time — 30 min
• Final feather humidity — 12%

All non-food poultry processing waste is processed into feed meal for livestock. This significantly reduces production costs and solves the problem of disposing of biological waste from poultry farms. The resulting meal is used as a valuable protein supplement in animal diets.

Raw materials for feed production include:

• soft slaughter waste (blood, intestines, lungs, kidneys, spleen, reproductive organs, cuticle of the gizzard);
• low-value bone by-products (heads and feet);
• carcasses of poultry that died or were culled during veterinary inspection;
• low-value feathers (wing feathers) and waste from feather and down processing enterprises;
• egg shells and incubation waste;
• culled day-old chicks;
• waste from sausage, culinary, and canning departments (bones, tendons, and defective finished products).

Table 66. Chemical composition of feed meal

Meat- | Meal |BloodBoneMeal bone from greaves feather Indicator grade |and| of and |1 pol | and | |p

Nitrogen-free matter content,| 2| 2| 2] 21 21| PP 1|-| — 4| 5 fiber (%), not more than

Poultry manure is a valuable waste. Each thousand laying hens produces about 50 tons of manure per year, which is used as a highly effective fertilizer. Calculated on a dry matter basis, manure contains 38—5% nitrogen, 3—4% phosphorus, 1.1—2.9% potassium. When poultry is kept on the floor using deep litter, manure is removed after all birds have been removed from the poultry house. The litter, together with the manure, is taken either to a manure storage facility for disinfection or directly to the field as fertilizer.

Table 67. Approximate manure yield from different poultry species

Approximate manure yield Species and age group of poultry (average per head) Adult poultry Egg-type chickens 240 Meat-type chickens 290 Turkeys 430 Ducks 550 Geese 600 Young stock Young chickens: from | to 30 days 30 from 31 to 60 days 80 egg-type from | to 60 days 55 meat-type from | to 60 days 90 egg-type from 61 to 150 days 120 meat-type from 61 to 150 days 150 egg-type from 1 to 140 days 98 meat-type from 1 to 150 days 180 egg-type from 151 to 180 days 210 meat-type from 151 to 210 days 240 Young turkeys: from | to 20 days 100 from 21 to 120 days 280 from | to 120 days 250 from 121 to 240 days 420 Young ducks: from | to 55 days 380 from 56 to 180 days 6 from | to 20 days 500 from 21 to 55 days 5 Young geese: from | to 20 (30) days 20 from 21 to 65 days 550 from 66 to 180 days 600 from 180 to 270 days 78°, Humidity of fresh chicken and turkey manure 83— 850/ [*)

Poultry houses are more often equipped with manure pits. In the center of the poultry house, running its entire length, there is a manure pit up to 1 m deep and about 5 m wide. Roosts are located above the pit with a wire mesh underneath, through which manure falls into the pit. If manure is removed via a conveyor, it is moved by a cross conveyor to a hopper or transport vehicle. A hard-surfaced area is prepared near the poultry house for the installation of transport equipment, and a heated structure is built on it during the winter.

In the facilities for caged laying hens, manure is collected from all tiers of cages by a special mechanism — a scraper. Then, the manure is fed into a belt conveyor hatch and moved to the end of the poultry house. The manure is transported into a metal container, which is then lifted by a hoist and tipped over the bed of a truck. Manure from poultry kept in cages is collected without bedding and is used either in dry form or dissolved in water.

The production of dry manure makes it possible to transport it at any time of the year over any distance. The most promising method is the manufacturing of dry granulated manure. Thermal treatment of manure destroys pathogens and weed seeds. The use of manure contributes to increasing the yield of fields, orchards, and vegetable gardens. Poultry farms have mastered the processing of chicken manure into organic acid, which is a valuable raw material for industry. On average, 12 kg of organic acid is obtained from each ton of chicken manure.

Scientific and technical progress is inextricably linked to improving product quality. In the current five-year period (1976—1980), the poultry processing industry must organize the production of new types of products that would not only meet world standards in terms of quality but in some cases even exceed them. APPLICATIONS ®

Table 1. Minimum productivity requirements for classifying egg-laying hens Economic popu- | Combined and sepa-| lations (purebred) | rate lines 'Elite- | record | I class | II class | Elite | I class | II class Characteristics Basic, Egg production per 68 weeks of | 260 | 230 | 220 | 200 | 220 | 200 | 190 life (pcs) Egg production per 39 weeks of | 80 | 70 | 65 | 60 | 65 | 60 | 55 life (pcs) Live weight at 52 weeks of age | 57 | 57 | 56 | 56 | 57 | 56 | 56 (g) Live weight at 39 weeks of age | 56 | 56 | 54 | 54 | 56 | 54 | 54 (g) Additional Chick hatchability from the number | 80 | 78 | 77 | 77 | 82 | 80 | 78 of eggs set (%) Survival rate of young hens up to | 93 | 92 | 91 | 90 | 95 | 94 | 92

Notes. 1. Requirements established for egg weight for poultry in the southern zone (Azerbaijan SSR, Armenian SSR, Georgian SSR, Kirghiz SSR) are reduced by 1 g. 2. Culling and mortality of adult poultry from 20 to 63 weeks must not exceed 35%. 3. Survival of young stock is taken as an average per batch. 4. Egg production per average laying hen.

Table 2. Minimum productivity requirements for classifying meat-breed hens

Combined lines; Economic populations maternal form paternal form dual-purpose breeds Characteristics elite- | I | II | elite- | I | II | elite- | I | II record | elite | class | class | record | elite | class | class | elite | class | class Basic Live weight at 8 weeks of age (g): | cockerels 1400 1300 1200 1000 1450 1350 1250 1150 1200 1100 1000 pullets 1200 1100 1000 900 1250 1150 1050 950 1000 900 800 Egg production per 64 weeks | 160 | 155 | 150 | 145 | 115 | 110 | 105 | 100 | 165 | 160 | 155 (pcs) Egg production per 34 weeks | 45 | 40 | 35 | 30 | 25 | 22 | 20 | 18 | 50 | 45 | 40 (pcs) Additional Chick hatchability from eggs set | 73 | 72 | 71 | 70 | 65 | 64 | 62 | 60 | 78 | 76 | 74 (%) Chick survival rate up to 8 weeks of | 95 | 94 | 93 | 92 | 93 | 92 | 91 | 90 | 95 | 94 | 93 age (%)

Notes. 1. When evaluating poultry by live weight at 9 weeks of age, the minimum requirements for this indicator listed in the table are increased by 12% for cockerels and by 10% for pullets. 2. Poultry of paternal lines must have excellent meat body conformation. 3. Culling and mortality of adult poultry aged 20 to 64 weeks must not exceed 35%. Survival is taken as an average per batch. 5. To evaluate poultry of grandparent and parent stocks by the live weight of young stock at 8 weeks of age, no less than 10% of the population of each batch (poultry house) is weighed individually.

Table 3. Determination of the grading class based on a set of characteristics class by egg weight for egg-laying hens or by live weight for meat-breed poultry class by egg production for meat-breed poultry Elite-record Elite-record | Elite-record Elite Elite | — Elite-record I class | — Elite-record Elite Elite II class | II class | Elite-record Elite Elite Elite Elite III class | III class | Elite | — | — | — | —

Table 4. Standards for metabolizable energy (kJ), crude protein, and mineral substances for poultry (% of mass of complete feed)

Metabolic energy, dry feed. Crude protein | Crude fiber | Calcium | Phosphorus | Sodium chloride | Species and bird age | (kJ) | (g) | (g) | (g) | (g) | (g) Adult birds Laying hens of egg-laying lines (cage and floor) Phase feeding of layers (days): 181—300 1134 17.0 | 667 5.5 | 3.1 0.8 0.4 301—420 1134 | 160| 7087 6.0 | 29 | 08 0.4 421 and older 1050 14.0 750 6.5 | 217 0.8 0.4 Laying hens of meat lines (days): 210—330 1134 16.0 | 7087 5.5 | 2.8 0.8 0.4 331 and older 1092 14.0 780 6.0 | 2.8 0.8 0.4 Turkeys 1176 16.0 735 6.0 | 2.5 0.8 0.4 Breeding toms 1176 16.0 735 6.0 | 1.5 0.8 0.4 Pekin ducks 1113 16.0 695.6 70| 2.5 0.8 0.4 Ducks of X-P cross 1134 17.0 667 7.0 | 2.5 0.8 0.4 Geese 1050 14.0 | 750 10.0 | 16 0.8 0.4 Young chickens of egg-laying lines (days): 1—30 1176 20.0 | 558 50 | 11 0.8 0.3 31—90 1092 17.5 | 624 5.0 | 1.1 0.8 0.3

Metabolic energy per 100 g dry feed (kJ) | Crude protein | Crude fiber | Calcium | Phosphorus | Sodium chloride | Species and bird age 91—150 1050 13.5 771.1 10| 1.2 0.8 0.4 Young chickens of meat lines (days): 1—30 1218 20.0 609 5.0 | 1.2 0.8 0.3 31-90 1155 115 | 660 5.5 | 1.2 | 08 0.3 91-180 1071 13.5 | 793.3 10| 13 | 08 0.4 Broilers (days): 1—30 1239 | 21 590 5.0 | 1.0 | 0.8 03 31 and older 1302 19 685.5 5.0 | 0.8 0.8 03 Turkey poults for meat (days): 1—60 1176 28 420 5.0 | 1.7 | 08 03 61—120 1179 | 22 5440 | 55|] 17| 038 0.4 121—150 (males) 1218 18 676.6 6.0 | 17 | 038 0.4 121—180 (replacement) | 1134 14.5 | 782 10| 1.5 | 08 0.4 Pekin ducklings for meat (days): 1—20 1155 18 641.6 5.0 | 1.2 0.8 0.4 21—55 1239 16 774.3 6.0 | 1.2 | 038 0.4 56—150 (replacement) 1050 14 750 10.0 | 1.5 0.8 0.4 Ducklings of X-P cross for meat (days): 1—20 1176 20 588 5.0 | 1.2 0.8 0.4 21—49 1218 18 676.6 6.0 | 1.2 0.8 0.4 50—196 (replacement) | 1176 13.5 | 8711 10.0 | 1.5 | 038 0.4 Goslings for meat (days): 1-20 1176 20 588 5.0 | 1.6 0.8 0.4 21—60 1176 18 653.3 10| 1.6 0.8 0.4 61—180 (replacement)! 1092 14 780.0 8.0 | 2.0 0.8 0.4

Note. For egg-laying and meat-line chicks in the first 2—5 days of life, it is recommended to provide compound feed, 100 g of which contains at least 1218 kJ of metabolic energy, at least 18 g of crude protein, no more than 5.5 g of fiber, calcium no more than 0.5 g, phosphorus no more than 0.7 g, and sodium up to 0.25 g.

Replacement young chickens of egg-laying and meat lines aged over 150—180 days (respectively) should be gradually transitioned to rations for adult birds.

Turkey poults, ducklings, and goslings intended for replacement purposes should be fed according to meat-type young stock standards during the initial stage, and thereafter according to the standards indicated in the table for the given period.

Table 5. Amino acid standards for poultry (% of complete compound feed)

Crude protein | Methionine | Isoleucine | Phenylalanine | Tyrosine | Arginine | Lysine | Leucine | Threonine | Valine | Histidine | Species and bird age Laying hens of egg-laying and meat lines 17 0.80 | 0.32 | 0.28 | 0.17 | 0.90 | 0.18 | 1.30 | 0.66 | 0.54 | 0.40 | 0.45 | 0.64 | 0.79 The same 16 0.75 | 0.30 | 0.27 | 0.16 | 0.85 | 0.17 | 1.28 | 0.62 | 0.51 | 0.37 | 0.43 | 0.60 | 0.74 14 | 0.65 | 0.26 | 0.21 | 0.14 | 0.74 | 0.15 | 1.12 | 0.54 | 0.45 | 0.37 | 0.53 | 0.65 Turkeys 16 0.80 | 0.32 | 0.25 | 0.15 | 0.86 | 0.22 | 1.20 | 0.50 | 0.55 | 0.35 | 0.10 | 0.70 | 0.50 Ducks 16 0.64 | 0.26 | 0.26 | 0.17 | 0.87 | 0.29 | 1.24 | 0.54 | 0.58 | 0.98 | 0.50 | 0.78 | 0.78 Geese 14 | 0.63 | 0.35 | 0.20 | 0.16 | 0.52 | 0.33 | 0.95 | 0.47 | 0.49 | 0.22 | 0.46 | 0.67 | 0.77 Young chickens of egg-laying and meat lines (days):

1—30 20 | 1.00 | 0.45 | 0.30 | 0.20 | 1.10 | 0.25 | 1.30 | 0.80 | 0.68 | 0.57 | 0.80 | 1.00 31—90 17.5 | 0.87 | 0.39 | 0.26 | 0.18 | 0.96 | 0.31 | 1.13 | 0.61 | 0.55 | 0.25 | 0.61 | 0.70 | 0.87 91—150—180 13.5 | 0.67 | 0.30 | 0.20 | 0.14 | 0.74 | 0.24 | 0.88 | 0.47 | 0.43 | 0.38 | 0.47 | 0.54 | 0.68

1—30 21 1.05 | 0.44 | 0.30 | 0.20 | 1.20 | 0.34 | 1.21 | 0.60 | 0.66 | 0.62 | 0.66 | 0.80 | 1.00

31—56 19 | 0.95 | 0.38 | 0.27 | 0.18 | 1.08 | 0.30 | 1.09 | 0.54 | 0.60 | 0.56 | 0.60 | 0.72 | 0.90 Turkey poults for meat (days):

1—60 28 1.50 | 0.52 | 0.48 | 0.30 | 1.50 | 0.60 | 1.60 | 0.84 | 0.80 | 0.80 | 0.70 | 0.90 | 0.90 61—120 22 1.20 | 0.41 | 0.28 | 0.24 | 1.20 | 0.50 | 1.25 | 0.66 | 0.65 | 0.63 | 0.55 | 0.71 | 0.70 121—150 (males) 18 0.96 | 0.33 | 0.32 | 0.19 | 0.96 | 0.28 | 1.08 | 0.58 | 0.22 | 0.51 | 0.45 | 0.56 | 0.56 121—180 (replacement) 14.5 | 0.80 | 0.27 | 0.26 | 0.16 | 0.80 | 0.32 | 0.86 | 0.45 | 0.48 | 0.12 | 0.28 | 0.48 | 0.48

1—20 18 1.00 | 0.45 | 0.25 | 0.20 | 1.00 | 0.40 | 1.50 | 0.50 | 0.80 | 0.40 | 0.55 | 0.80 | 1.00 21—55 16 0.89 | 0.40 | 0.22 | 0.18 | 0.89 | 0.36 | 1.38 | 0.44 | 0.70 | 0.35 | 0.48 | 0.78 | 0.89 56—150 (replacement) 14 0.78 | 0.35 | 0.19 | 0.16 | 0.77 | 0.32 | 1.16 | 0.38 | 0.23 | 0.30 | 0.43 | 0.62 | 0.78

1—20 20 | 0.50 | 0.28 | 0.22 | 0.14 | 1.67 | 0.56 | 0.89 | 0.48 | 0.61 | 0.89 | 1.00 21—49 18 1.00 | 0.45 | 0.25 | 0.20 | 1.00 | 0.40 | 1.50 | 0.20 | 0.80 | 0.39 | 0.55 | 0.30 | 1.00 50—196 (replacement) 13.5 | 0.75 | 0.34 | 0.18 | 0.15 | 0.74 | 0.31 | 1.12 | 0.37 | 0.51 | 0.29 | 0.41 | 0.60 | 0.75

1—20 20 1.00 | 0.50 | 0.28 | 0.22 | 1.00 | 0.47 | 1.66 | 0.67 | 0.83 | 0.27 | 0.61 | 1.05 | 1.10 21—60 18 0.90 | 0.45 | 0.25 | 0.20 | 0.90 | 0.42 | 1.49 | 0.60 | 0.70 | 0.33 | 0.55 | 0.94 | 0.99 61—180 (replacement) 14 | 0.70 | 0.35 | 0.20 | 0.16 | 0.70 | 0.33 | 1.15 | 0.47 | 0.57 | 0.26 | 0.48 | 0.73 | 0.77