Chicken Meat Processing Model

This model focuses on the core steps involved in transforming live chickens into
various marketable meat products. It emphasizes hygiene, safety, and quality control
throughout the process.

Inputs:

 Live chickens
 Water
 Electricity
 Processing equipment (scalders, pickers, eviscerators, chillers, etc.)
 Packaging materials (trays, bags, wraps)
 Optional: Seasonings, marinades, further processing equipment

Outputs:

 Fresh whole chickens

 Chicken parts (breasts, thighs, wings, drumsticks)
 Further processed products (ground chicken, sausages, nuggets, etc.)

Process Steps

1. Receiving and Inspection

Live chickens arrive at the processing facility and undergo a health

inspection to ensure they meet quality and safety standards.

2. Stunning and Slaughter

Chickens are humanely stunned using controlled electrical current or CO2

inhalation to minimize pain and suffering. Following stunning, they are humanely
slaughtered.

3. Scalding and Feather Removal

The chickens pass through a hot water bath (scalding) to loosen feathers,
followed by automated pickers that remove them effectively.

4. Evisceration and Cleaning

The internal organs, feet, and head are removed in a dedicated

evisceration line. The carcass is thoroughly cleaned with chlorinated water to
remove any remaining contaminants.

5. Chilling
 The cleaned carcasses are immersed in a cold-water bath or air-chilling
system to rapidly lower their internal temperature, preventing bacterial growth
and ensuring food safety.

6. Inspection and Grading

Government inspectors examine the carcasses for any abnormalities or

diseases. Additionally, the chickens are graded based on factors like size,
conformation, and fat content.

7. Deboning and Cutting (Optional)

For further processing, the meat can be deboned using mechanical

separators or by hand. The deboned meat can then be cut into various parts
(breasts, thighs, wings, drumsticks) or ground into different shapes and sizes.

8. Processing and Packaging

Depending on the final product, the meat can be further processed with
additional ingredients (seasonings, marinades) or shaped into specific forms
(sausages, nuggets). Finally, the processed meat products are packaged in
appropriate materials for storage and distribution.

9. Storage and Distribution

The packaged products are stored and transported under controlled

temperature and hygiene conditions to maintain freshness and quality until they
reach retailers and consumers.

Quality Control

Throughout the process, strict quality control measures are implemented to

ensure food safety and product consistency. This includes regular equipment cleaning
and sanitation, temperature monitoring, and sampling for potential contaminants.

Additional Considerations:

 Animal welfare practices are crucial throughout the process, ensuring humane
treatment of chickens.
 Environmental regulations regarding wastewater treatment and waste disposal
must be followed.
  Different processing facilities may incorporate variations or additional steps
depending on their specific equipment, product offerings, and local regulations.

This process model provides a general overview of the chicken meat processing
journey. It is important to acknowledge that ethical considerations and responsible
practices remain critical aspects of the entire system.

Chicken Meat Processing Model

Receiving and Inspection Stunning and Slaughter Scalding and Feather Removal
 Inspection and Grading Chilling Evisceration and Cleaning

Deboning and Cutting Processing and Packaging Storage

(Optional)

Distribution

Chicken Meat Processing Flowchart

Step Description Decision Point Yes No Next Step
Receive
1 Live Chickens arrive at the facility. - - 2
Chickens
Doesn't
Trained personnel examine Meets Reject
2 Inspection meet
chickens for health and quality. standards? chickens
standards
Chickens are stunned
Stunning &
3 humanely to minimize suffering - - 4
Slaughter
before slaughter.
 Scalding & Hot water bath loosens
4 Feather feathers, followed by - - 5
Removal automated pickers for removal.
Internal organs, feet, and head
Evisceration are removed. The carcass is
5 - - 6
& Cleaning thoroughly cleaned with
chlorinated water.
Carcasses are immersed in
6 Chilling cold water or air-chilled to - - 7
rapidly lower temperature.
Government inspectors
examine carcasses for
Inspection abnormalities and diseases. Reject
7 Approved? Rejected
& Grading Carcasses are graded based carcasses
on size, conformation, and fat
content.
Meat is deboned mechanically
Deboning & Proceed to
or by hand (for further
8 Cutting further No 9
processing). Deboned meat
(Optional) processing?
can be cut into parts or ground.
Whole chickens or parts are
9 Packaging packaged in appropriate - - 10
materials.
Deboned meat is further
Processing processed with additional
& ingredients or shaped
10 - - 10
Packaging (sausages, nuggets).
(Optional) Packaged in appropriate
materials.
Packaged products are stored
Storage & and transported under
11 - - End
Distribution controlled temperature and
hygiene.
 Receive Live
Chickens

Inspection

No
Meets
Reject
standard?
Chickens
Yes or No

Yes

Stunning &
Slaughter

Sca l ding &

Fe a ther Removal

Evisceration &
Cleaning

Chill ing

Inspection &
Gradi ng

Rejected
Approved (Optional)
Reject Deboning
carcasses or
& Cutting
Rejected?
(Optional)
Approved

(Optional) Processing
Packaging &
Packaging

Storage &
Di stri bution