Chapter I

INTRODUCTION

Background of the Study

Poultry meat is popularly consumed among non-vegetarians

world-wide due to its low fat and calorific content. The relatively
increased preference for chicken over some other type of meat has
generated keen interests in poultry farming and processing industry.
Likewise, with the growing world population livestock consumption rate
may have to increase correspondingly to meet the effective protein
requirement of the world. Poultry processing has faced challenges that
are of safety and health concern some of which include tasks that could
result in cuts or lacerations, repetitive motion disorders, slips and falls,
exposure to cold and wet climates, dust, dermatitis, chemicals, and
noise (Barbut , 1998, Barbut, 2002; OSHA, 2004).
To avoid accidents and infections form poultry carcasses which
may occur during some of the processing operations there is need for
user-friendly, reliably and efficient poultry processing devises (Ralph,
1980; Scolt, 2000).
A number of important activities are involved in the production
of ready-to-cook poultry a large percentage of which are labour
intensive and these contribute to the high cost of processed poultry
meat in the market. Identified production processes for eviscerated
birds are (1) Pre-slaughter: catching and transport; (2) Immobilizing,
killing, and bleeding, (3) Feather removal: scalding and picking, (4)
Removal of head, oil glands, and feet, (5) Evisceration, (6) Chilling, (7)
Cut-up, deboning, and further processing, (8) Aging, (9) Packaging, (10)
Storage and (11) Distribution. Among the listed processes feather
removal is the most time consuming and risky next to eviscerating
process especially when carried out manually (Dicken and Shackelford,
1998).

Removing feathers by hand is the traditional means and method

of removing feathers from poultry species. For certain reasons,
removing feathers by hand was becoming obsolete since the inception
of industrial age. Development of a poultry de-feathering machine is a
process of producing a mechanical means of removing feathers from
scalded birds (Adetola et. Al, 2014).

Further, the manual defeathering method exposes workers to

work musculoskeletal disorder, cuts, skin rashes, dermatitis and avian
influenza virus. Solutions to some of these problems were suggestions
from research findings (Scolt, 2000). The energy audit of some poultry
processing plants with specific survey of five deferent relevant unit
operations revealed that scalding and de-feathering is the most energy
intensive unit operation accounting for 44% of the total energy
consumption in the processing (Jekayinfa, 2007). Level of human
exposure to occupational risk and other health hazard resulting from
intense manual operation is significant in scalding and de-feathering
operations. This calls for effective mechanization of the process which
will support quality, safe, ergonomic and economic operation. Various
machines have also been developed for de-feathering process which can
handle either large or few number of birds (Glenn, 1998). However, their
demand and acceptance are different from one country to the other.

For this paper, the development of the plucking machine in

poultry processing is hoped to contribute tremendously to the
successful processing of dressed and hygienic chicken for consumption
and it will also minimize disease infection. It had overcome the
drudgery, time consumption and discouragement associated with hand
plucking. Against this background, this work designed and fabricated
a de-feathering machine for small scale processors which could pluck
chicken at the market standard.
Significance of the Study

This study will produce a mechanical defeatherer for poultry

animals with an automated scalder for small-scale use. It has been
reported that today’s mechanized plucker are mostly used in large
scale. Prior to defeathering, the scalding process necessitates the use
of a separate machine. In this paper, the researcher fabricated a
machine placing both the defeatherer and scalder into a single unit. The
scalder was composed of water heaters controlled by sensor switches
tested to obtain the optimal scalding temperature. The aimed at
addressing the problem on the drudgery of poultry processing since the
two processes were placed side by side.

Objective of Study

The primary objective is to produce a mechanical equipment to

be used for the scalding and defeathering of poultry animals.
Specifically, it aims to:
A. Design and fabricate a Mechanical Defeatherer for Poultry
Animals with an Automated Scalder;
B. Test and evaluate the performance of the machine in terms of:
a. Scalding Capacity, kg/hr
b. Defeathering Capacity, kg/hr
c. Defeathering Efficiency, %

Scope and Limitation of the Study

The study will focus only on the design, fabrication, and

performance evaluation of Mechanical Defeathering Machine for Birds
with an Automated Scalder. The machine will be assessed in terms of
scalding capacity (kg/hr), defeathering capacity (kg/hr), defeathering
efficacy (%) and defeathering efficiency (%). Native chicken, broilers and
ducks will be used as test materials.
Operational Definition of Terms

To establish accurate and precise understanding of the study,

the following terms are hereby defined:

Defeathering process of removing the feathers from

the skin of poultry animal after scalding
as part of preparing its meat for food.

Defeathering Capacity maximum weight of poultry animals the

machine is capable of defeathering per
unit time, expressed in kilograms per
hour.

Defeathering efficiency ratio of amount of feathers removed and

the total amount of poultry feathers,
expressed in percent.

Defeatherer/Plucker mechanical assembly equipped with

rotating device with attached rubberized
fingers that removes the feathers from
the poultry animal after scalding.

Feather one of the light, flat growths forming the

plumage of poultry animals, consisting
of numerous slender fibers, forming a
vane on either side of partly hollow
shaft.

Poultry birds that are usually domesticated for

their eggs, meat and feathers (e.g.
chicken, geese, turkeys, ducks, and
ostriches).

Rubber fingers defeathering mechanism made of rubber

materials and are being used to pluck
 feathers from the poultry animal’s skin
during defeathering operation.

Scalder slaughterhouse equipment that

contains hot water with specific
temperature that is being used to loosen
and facilitate removal of poultry animal’s
feathers from its skin and for partial
sanitation purposes.

Scalding process of subjecting poultry animal to

steam or hot water to loosen feathers
from its skin prior to defeathering.
 Chapter II

REVIEW OF RELATED LITERATURE AND STUDIES

This chapter presents the review of related literature and studies as

well as the research paradigm sourced from other researchers and
studies mostly published online.

Review of Related Literature and Studies

This project study focused on the process of using the old

and/or existing technology found on the patent documents and even in
the existing chicken defeatherer and scalder. The researchers refer to
the following previous design and literature relating to dry. Figure 1
shows the process flow of the existing practice of using the old
technology.

Analysis of the Problem

Figure 1 diagrammatically shows the general process of plucking

the feathers of the poultry. The process generally uses two separate
machines, the scalding machine and the plucking machine. It is started
by dipping wholly the chicken into the basin of a water at certain
allowable temperature enough to initiate the removal of the feathers.
After the scalding process, the chicken is then immediately introduced
on the plucking machine. The machine is then turned on which
operates at specific rotational speed and time duration enough to
remove all the associated feathers.
 Step 1
Scalding are mostly initially done through immersion with
preheated water of which temperature is commonly identified
through manual estimation.

Step 2
Using a separate machine, the scalded poultry at certain number
are then loaded into the plucker.

Step 3

The chicken is defeathered at specific speed and time duration

securing a clean and blemish free whole dressed chicken.

Figure 1: Existing Process Flow of Scalding and Defeathering Poultry

Animals.

Broiler Meat Production

This statistic depicts the global broiler meat production in 2018,

broken down by country. In that year, the United States were the
world's leading country in broiler meat production with an amount of
about 19 million metric tons. From the same table, Brazil comes 2nd
with 13, 375 tons, European Union with 12,000 tons, China with
11,000 tons, India with 4,600 tons, Russia with 4,000 tons, Mexico with
3, 500 tons, Turkey with 2,250 tons, Argentina with 2,110 tons,
Thailand with 1,965 tons and Malaysia with 1,710 tons (statista.com).
 Figure 2: Worldwide Production of Broiler Meat

Poultry Industry in the Philippines

Performance of Philippine Agriculture, October-December 2017

The livestock subsector which shared 17.78 percent in the total
agricultural production came up with a 1.84 percent output gain in the
fourth quarter of 2017. Hog production, which was the major source of
subsector’s growth, increased by 2.75 percent. The subsector
grossed PhP85.5 billion at current prices, representing a 14.39
percent increase over last year’s record. On an annual basis, the
subsector’s gross output was up by 1.12 percent 2017.
 Poultry production expanded by 4.73 percent in the fourth
quarter of 2017. It accounted for 15.40 percent of the total agricultural
output. Except for duck, all components of the subsector posted output
gains. At current prices, the subsector grossed PhP59.3
billion, or 15.22 percentmore than the previous year’s gross receipts.
For the whole year of 2017, the gross output of the poultry subsector
went up by 4.62 percent (Statistica.com).

Poultry Production in Region XI

The total count of chicken in the region, as of January 1, 2018,

remarkably dropped to 11,655,512 birds. This recorded a 15.36 percent
decline from the previous year’s level of 13,770,535 birds. The inventory
of broilers, layers, and native/improved chickens registered decreases
of 36.99 percent, 12.87 percent and 2.85 percent, respectively.
As of January 1, 2018, the native/improved chicken had the
largest stock share with 63.80 percent to the total chicken inventory in
Davao Region. This was followed by broiler chicken with 24.87 percent
share. Layers had the least number with only 11.33 percent share to
the total stocks.
 Figure 3: Davao Region Poultry Production 2017

Classification of Scalding Machine

According to PAES 529:2012, the classification of the scalder

shall be based on the following:

1. Through Immersion

Type of scalder where poultry animals are being submerge for

scalding.

2. Through Spraying

Type of scalder where the heated water is evenly sprayed on the

poultry animal’s body for scalding.

Scalding Capability

Based on PAES 529: 2012, scalding capability is classified as

hard scalding, medium scalding and soft scalding.

1. Hard Scalding
Type of scalding that results into easier removal of feathers and
loosens the stratum corneum (cuticle) of skin surface. This type of
scalding produces a skinless carcass.

2. Medium Scalding

Type of scalding that is appropriate for mature poultry animals

whose feathers are more difficult to remove. This type of scalding
produces carcass with pinkish skin.

3. Soft Scalding
 Type of scalding wherein the feathers are loosened without
causing appreciable damage to the outer layers, the cuticle or skin
surface. This type of scalding produces carcass with skin containing a
waxy yellow-pigmented layer.

Defeathering Machine Orientation

1. Vertical type

Type of defeathering machine in which the defeathering

drum/chamber is rotating with the aid of a vertically installed shaft.
This type of defeathering machine is intended for small-scale poultry
dressing/slaughtering plant where batch type loading of poultry
animals to the machine is necessary.

2. Horizontal Type

Type of defeathering machine wherein the defeathering mechanism

rotates with horizontally installed shaft. This type of defeathering
machine is intended for large-scale poultry dressing/slaughtering plant
where poultry animals are automatically and continuously loaded.

Prior Art 1
 Figure 4: The Pluckers Brothers invented by Everett T. Conaway

Inventor : Everett T. Conaway

Current Assignee : Plucker Brothers, LLC

Original Assignee : Everett T. Conaway

Priority date : 2003-08-26

Description :

Apparatus for de-feathering (i.e. picking or plucking) poultry.

More particularly, picking apparatus employing a plurality of elongated
picking elements which are resistant to cracking and/or micro-poring,
and which are preferably flexible and/or bendable and which are of
sufficiently low mass such as to decrease poundage yield loss (e.g.
decrease fat loss and poultry wing damage). In some embodiments,
apparatus is provided having a plurality of filaments rotatable about an
axis for removing feathers from a poultry carcass.

Prior Art 2
 Figure 5: The chicken plucking machine invented by Wathes, et al

Inventor : Christopher Michael Wathes, et al

Current Assignee : BTG International Ltd

Original Assignee : BTG International Ltd

Priority date : 1993-11-26

Description :

A plucking unit, apparatus or equipment (25) for plucking poultry

carcasses on a shackle line (26) including a plurality of individual
plucking units (10), one for each of a number of carcasses to be plucked
at any one time, and shielding means (12) included in or provided
additionally to, said plucking units (10) whereby the plucking heads of
each said unit are shielded from the plucking heads of the neighboring
units during plucking.

Prior Art 3

Figure 6: The scalding tank invented by Harry J Long

Inventor : Harry J Long

Current Assignee : JBS USA LLC

Original Assignee : JBS USA LLC

Priority date : 1950-08-01

Description :

It has long been the practice to scald poultry by dipping the birds
in hot water before attempting to pick the feathers therefrom. In
commercial operations, this is commonly performed by attaching a
clamp to the legs of the birds and moving the clamp and bird supported
thereby along a given path by means of an overhead conveyor, which
path intersects a scalding tank through which the birds are dragged.
The length of time that the bird remains in the scalding tank is
determined by the speed of the conveyor. The amount of scalding
(controlled through the scalding temperature and immersion time) is at
best a compromise, The more the birds are scalded, the more easily may
the feathers be removed therefrom. However, if the birds are scalded for
too long a period, the rubber fingers of the mechanical pickers used in
the defeathering will bark or otherwise spoil the appearance of the skin
and result in a less saleable product.

Prior Art 4

Figure 7: The scalding tank invented by Shrauger Darius E

Inventor : Shrauger Darius E

Patent Number : US1660583 A

Priority date : Feb 28, 1928

Description :

The invention is to provide a scalding tank for fowls of simple,

durable, and comparatively inexpensive construction. A further object
of my invention is to provide a scalding machine in which fowls may be
conveniently placed and conveniently removed after they have been in
the machine a predetermined length of time. More particularly it is
object to provide a machine of this character in the form of tank adapted
to contain hot water for the purpose of scalding the fowls and a means
of suspending the fowls in the water. Still a further object is to provide
the suspending means continuously movable so that after the fowls
have been placed in the water they will be carried by the suspending
"means through the water a predetermined length of time after which
they may be removed from the tank.
 Chapter III

MATERIALS AND METHODS

This chapter highlights all the working materials, tools and

equipment employed in the conduct of the study.

Materials Used

Listed below were the material needed for the construction of the
machine. The materials are presented with their specifications. All were
available in the market.

1. 2 Length Angle Bar (3/16x1x3.0)

2. Aluminum plain sheet
3. 2 pcs Caster wheel w/ Lock (2”)
4. 2 pcs 1” Ø Pillow Block bearing UCF (205)
5. 1” Ø Mild Steel Shafting
6. 1pc V Belt
7. 12” and 6” Ø pulley
8. 4 ft x 8 ft stainless steel sheet (304 coating, 1.2mm thick)
9. 1 hp Electric motor
10. 5 pcs ½” Bolt, Nut
11 5 pcs ¼” Bolt, Nut
12. 1 pc digital temperature sensor
13. 1 pc 3.5” Ø Pulley
14. Plain Sheet Galvanized Iron (4 mm)
15. 3m hose (1/2 Ø)

16. 120 pcs rubber fingers

17. 2 pcs. Switch

18. 1 pc heater
Tools and Equipment Used

The tools and equipment to be used during the fabrications will

be the following;

1. Welding machine

2. Electric portable grinder

3. Electric hand drill

4. Steel tapes

5. Steel square

6. Screw drivers

7. Hammer

8. Hacksaw

9. Try square

10. Drill bits

11. Pliers

Study Procedural Framework

All materials to be employed in the construction will be gathered

from locally available sources and were produced at varied forms and
classifications. All components will be made of standard materials
except for the mainframe and other parts not in contact with the poultry
shall be made of stainless materials. Using the gathered materials,
individual parts will be fabricated according to their size and other
notable specifications. These parts will then be assembled to its final
form. The machine will be pre – tested to identify potential
improvements. Modifications was done to achieve the desired
performance before it will be used on the final testing. Machine
evaluation involving the study parameters was conducted.

Description of the Machine

Figure 8. Perspective View of the Mechanical Defeatherer for Poultry

Animals with Automated Scalder

The machine was mainly be composed of a cylindrical plucker

with rubber fingers, main frame, scalder basin. The scalding process
was automated using a digital thermostat which has direct control in
the turning on and off of the heater.
Exploded Design of the Machine

Figure 9: Exploded View of the Mechanical Defeatherer for Poultry

Animals with Automated Scalder

Figure 10. Isometric View of the Mechanical Defeatherer for Poultry

Animals with Automated Scalder
 15 cm 55 cm

5 cm
Figure 11: Back view of the Mechanical Defeatherer for Poultry
Animals with Automated Scalder

Figure 12: Right side view of the Mechanical Defeatherer for Poultry
Animals with Automated Scalder
 Figure 13: Left side view of the Mechanical Defeatherer for Poultry
Animals with Automated Scalder

Figure 14: Top view of the Mechanical Defeatherer for Poultry Animals
with Automated Scalder
Figure 15: Top view of the Mechanical Defeatherer for Poultry Animals
with Automated Scalder

Figure 16: Top view of the Mechanical Defeatherer for Poultry Animals
with Automated Scalder
Figure 17: Front view of Rubber Finger

SHAFTING

Figure 18 Details of Rubber Finger

New Process Flow

Step 1
Scalding was done through immersion with preheated water of
which certain temperature is maintained using temperature
sensors.

Step 2
The scalded poultry at certain number are then loaded into the
plucker conveniently since it does not use a separate machine.

Step 3
The chicken is defeathered at specific speed and time duration
securing a clean and blemish free whole dressed chicken.

Figure 19: New process of chicken scalding and plucking.

Performance and Evaluation

Once the defeathering machine for poultry animals with

automated scalder is completed, its two major components were
individually evaluated to identify its overall efficiency and capacity and
to know the limitations of the machine for further development. The
evaluation was done in triplicates and the mean was reported. Below
was the major procedure employed during the evaluation:

1. Nine birds (three native chickens, three broilers and 3 ducks)

were purchased at the nearby Panabo and Tagum Public
Markets.
 Figure 20: Purchasing of Live Poultry Animals in the Markets

2. The live weight of the birds was identified to secure that the test
materials are close in terms of weight. It was done to attain a
more accurate and precise data.

Figure 21: Weighing of the Slaughtered Poultry Animals.

3. After getting the weight, the poultry animals were then stunned
and slaughtered.

Figure 22: Manual Slaughtering of the Poultry Animals

4. During the scalding, the birds were immersed in the scalder for a
specific time at specific scalding temperature, set according to the
Philippine Agricultural Engineering Standard (PAES 529). Native
chicken (T1) were soaked 45 seconds at 80°C scalding
temperature; Broiler (T2) within 90 seconds at 55°C; and ducks
(T3) within 120 seconds at 80°C.
 Figure 23: Scalding Process of the Poultry Animals

5. Defeathering shall be done immediately after proper scalding of

the poultry animals.

Figure 24: Defeathering Process of the Poultry Animal

 6. Weight of the plucked and non-plucked feathers were noted.
7. The weight of the dressed chicken was recorded.

Figure 25: Data collection on the weight of the dressed poultry

animals and the plucked feathers.

Formula to be Used

The machines overall capacity and product recovery were

calculated using the following formula. Other parameters relevant to
the study were also computed.

A. Scalding Capacity, kg/hr

Maximum weight of poultry animals the machine is capable

of scalding per unit time, expressed in kilograms per hour

 Maximum weight of Poultry Animals in the machine (kg)
SC = 𝑥 100
Total operating time, (hr)

B. Defeathering Capacity, kg/hr

Maximum weight of poultry animals the machine is capable

of defeathering per unit time, expressed in kilograms per hour.

Maximum weight of Poultry Animals in the machine (kg)

SC = 𝑥 100
Total operating time, (hr)

C. Defeathering Efficiency, %

It is the ratio of amount of feathers removed and the total

amount of poultry feathers, expressed in percent

total weight of feathers removed (kg)

Eff = 𝑥 100
Total weight of feathers , (kg)

Data Analysis

This study used appropriate statistical tools to properly present

statistical data. Mean is the sole tool used in analyzing the gathered

data. It is the average that is used to derive the central tendency of the

data in question. It is determined by adding all the data points in a

population and then dividing the total by the number of points.

Costing of the Study

The table below represents the cost of the materials that will be
used in the fabrication Mechanical Defeatherer for Poultry Animals with
Automated Scalder.

Table 1. Cost of the Supplies and Materials

Unit Item Description Quantity Unit Cost Total Cost

unit 1” Ø Mild steel 1 600.00 600.00

shafting 2 ft.

pcs PLAIN SHEET 2 950.00 1900.00

pcs 6” Ø pulley 2 150.00 300.00

pcs 1” Ø Pillow block 2 250.00 500.00

bearing UCF type

pcs 3 120.00 120.00

pcs Rubber Finger 97 1,338.00 1338.00

unit 1. 220 V (AC), 1740 1 2500.00 2500.00

rpm, 1hp Electric
motor

pcs 1/12 bolt, nuts & 40 30.00 60.00

washers

pcs 12” Ø pulley 1 175.00 175.00

pcs Pipe stainless steel 1 500.00 500.00

3’’ sch.40

unit Angle Bar 2 400 1200.00

(3/16x1x3.0)

pcs MS plate 12mm thick 1 200.00 200.00

TOTAL Php9,393.00
Study Timeframe

Table 2. Completion Time Frame of the Study

TASK Mar Apr May Jun Jul Aug Sep Oct

Initial Planning
of the Project

Designing and
Planning of the
Project

Research write-
up (Chapter1-3)

Procurement of
Supplies and
Materials

Construction
Assembly and
Fabrication
Procedure

Pilot- testing
and Revising of
Malfunctioned
Parts

Evaluation of
the project

Research write-
up
(Chapter 4-5
and
Preliminaries)
Editing of
manuscript and
packaging of
paper