Poultry Meat Processing & Further Processing : Bangladesh

Poultry meat processing and further processing is a growing industry in Bangladesh. The industry started flourishing in the nineties. The first chicken meat processing industry was set up by Aftab Bahumukhi Farms Ltd. at Bajitpur, Kishoregonj.

The major players in this business are:

Poultry Processing:

• ✓Aftab Bahumukhi Farms Ltd.
• ✓AG Agro
• ✓BRAC
• ✓CP Bangladesh
• ✓Paragon Group
• ✓Eon Group
• ✓ATR

Poultry Further Processing:

• ✓Kazi Farms Ltd.
• ✓Aftab Bahumukhi Farms Ltd.
• ✓Paragon Group
• ✓CP Bangladesh
• ✓Golden Harvest
• ✓Quality
• ✓Eon Group
• ✓Essential
• ✓PRAN Group
• ✓ATR
• ✓AG Agro
• ✓Bengal
• ✓Lamisa
• ✓Nourish Poultry
• ✓Shopno Agro
• ✓Roja (Rangs)
• ✓Hollyseed

Processed Chicken

Processed chicken is chicken meat that has either been mechanically recovered from a chicken carcass or is made of a combination of chicken meat and skin. Many different types of processing can be done on other meats, but processed chicken is primarily either mechanically recovered or is made from ground up chicken meat and formed into shapes. Any meat that has gone through a process such as drying, fermenting, curing, or pre-cooking can be classified as processed meat.

The most common bits of a chicken used for food are the :

• ✓Breasts,
• ✓Legs, and
• ✓Wings

Processing makes other parts of the chicken edible. During the processing of a full chicken carcass, the valuable cuts such as the breasts, legs and wings are removed. The leftover carcass is often used to mechanically recover the leftover meat. Depending on how the more valuable cuts of meat are going to be used, they may or may not be processed into another form. Foods such as chicken frankfurter are made from processed chicken, using a mixture of lean meat and chicken skin. Chicken bologna is also made from these processed parts.

The carcass is ground up, along with cartilage, bones, and skin, in order to recover the meat that can be still garnered from the chicken. The processed chicken then comes out in a pink mousse, brimming with bacteria, waiting to be treated with ammonia to kill the microorganisms. The chicken is then re-colored in order to make it conform to expectations of what chicken looks like and re-flavored to remove the ammonia taste.

This mixture of processed chicken is then used in a variety of different food products in place of more expensive lean chicken. Products which make use of mechanically processed chicken include chicken ham in the US, or chicken meat balls in Asia. This process is often thought to be used in the making of chicken nuggets, but while the meat is still technically processed in most chicken nuggets, it cannot be said to be mechanically processed. Other types of processing include drying, frementing, curing, or pre-cooking.

Halal Chicken

The specialty of Bangladeshi processed and further processed chicken products is its superior quality and Halal slaughtering.

All the local brands are producing Halal Chicken Meat and Meat products as majority of the Bangladeshis are Muslims. The companies have Halal certification as well. The local brands are preparing to enter into the global export market. They also have special interest about the Halal Market.

Chicken Processed products :

Further Processed Chicken Products

General Queries about Poultry Processing

What is poultry processing?

Poultry processing is the term used by the poultry industry to describe the conversion of live poultry into raw poultry products fit for human consumption.

What is ante-mortem inspection?

Ante-mortem inspection examines the live birds for signs of disease. Live birds that are not healthy are not fit for human food and are condemned.

How do establishments slaughter live birds?

The most common slaughter method is cutting the major blood vessels in the neck followed by blood loss. Most poultry slaughter establishments render the live bird insensible to pain prior to making the cut. Some religious dietary requirements preclude rendering the live bird insensible to pain.

How do establishments remove feathers?

Feather removal is a two-step process. Establishments first immerse carcasses in hot water to loosen the feathers. Then they pass the carcasses through machines that physically remove the feathers.

What is post-mortem inspection?

Post-mortem inspection examines the carcass for evidence of disease or defects. Diseased carcasses are unfit for human food and are condemned. If reprocessing can remove a defect and make the carcass fit for human food, the establishment can save the reprocessed carcass.

How does FSIS inspect the carcass?

Inspection program personnel observe the external and internal surfaces of each carcass. They also observe and palpate the internal organs. Based on their inspection findings, they either condemn the carcass or pass the carcass for human food.

What is carcass re-inspection?

Re-inspection examines reprocessed carcasses to ensure the removal of defects. If the establishment fails to remove the defects, inspection program personnel retain the product and prevent its use as human food.

What are sanitation performance standards?

Sanitation performance standards are regulatory requirements designed to prevent insanitary conditions within the poultry processing facility. Inspection program personnel perform daily inspections to ensure that poultry processing establishments meet the sanitation performance standards.

What are sanitation standard operating procedures?

Sanitation standard operating procedures are regulatory requirements designed to prevent direct contamination of product during processing. Inspection program personnel perform daily inspections to ensure that poultry processing establishments effectively implement sanitation standard operating procedures.

What is a hazard analysis and HACCP plan?

A hazard analysis and HACCP plan are regulatory requirements designed to identify and control physical, chemical, and biological food safety hazards. Inspection program personnel perform daily inspections to ensure that poultry processing establishments meet the hazard analysis and HACCP plan requirements.

What is a regulatory control action?

A regulatory control action is retention of product, rejection of equipment or facilities, or refusal to allow processing. Inspection program personnel take a regulatory control action whenever they determine that the establishment failed to meet the sanitation performance standards, sanitation standard operating procedure, or hazard analysis and HACCP plan requirements.

What physical, chemical, and biological food safety hazards occur in raw poultry products?

Physical and chemical food safety hazards rarely occur in raw poultry products. Pathogenic bacteria are the most significant biological food safety hazards associated with raw poultry products. Salmonella Enteritidis and Campylobacter jejuni are pathogenic bacteria associated with human illness. FSIS conducts microbiological sampling programs to monitor raw poultry products for the presence of pathogenic bacteria.

Can poultry processing completely eliminate harmful bacteria?

No. Poultry processing cannot eliminate harmful bacteria. Poultry processing conducted in accordance with regulatory requirements prevents, to the maximum extent possible, harmful bacteria from occurring on raw poultry products.

Can raw poultry become unsafe after purchase?

Yes. Raw poultry is not sterile. Holding raw poultry between 40 °F and 140 °F (4.4 °C and 60 °C) allows bacteria to grow. Minimizing the time between grocery store and refrigerator and between refrigerator and cooking, will minimize the risk of bacterial growth.

Is rinsing, washing, or soaking raw poultry before cooking necessary?

No. Rinsing, washing, or soaking is not necessary. Proper handling after purchase will minimize the consumer's risk of exposure to bacteria. Rinsing, washing, or soaking raw poultry does not destroy bacteria, but does increase the risk of contaminating other foods, utensils, and surfaces. Proper cooking will destroy any bacteria present on raw poultry.

Follow the four steps of the Food Safe Families campaign:

• ✓CLEAN. Wash hands and surfaces often.
• ✓SEPARATE. Do not let raw poultry or its juices touch other foods.
• ✓COOK. Cook poultry to the safe minimum internal temperature of 165 °F (73.9 °C) as measured with a food thermometer.
• ✓CHILL. Refrigerate poultry promptly.

(https://www.fsis.usda.gov/wps/portal/fsis/home)

Steps of Poultry Meat Processing

A. Shackling

1. Poultry meat processing is initiated by hanging, or shackling, the birds to a processing line.

2. Birds are transferred from coops or transport cages to a dark room where they are hung upside down from shackles attached to an automated line.

B. Stunning

1. Electrical stunning delivers a current through a water bath to immediately create a state of unconsciousness. For a complete stun, birds must receive a particular electric exposure for a specified time. An effective stun will cause the bird to arch the neck, hold the wings tightly to the body, sometimes result in body tremors and will render the bird unconscious immediately and lasting until the bird has been killed. The current should be compliant with minimum recommended current / bird.

2. Controlled environment stunning is another alternative stunning process. Birds are immersed in an approved gas or mixture of gases (i.e., CO2) in order to displace oxygen and render the bird unconscious.

C. Bleeding

1. After stunning, the birds are passed through an automated knife that makes an incision on the neck to cut the major blood vessels in the neck.

2. With the carcass hanging upside down and the major blood vessels cut, the majority of the blood in the carcass will exit.

D. Scalding

1. Scalding loosens the feathers to facilitate their removal.

2. Carcasses are submerged into the scalder that contains water heated from 125-150 F, depending upon the type and age of the poultry.

3. This high water temperature serves to loosen the connection of feathers to the skin.

E. Picking

1. Picking is a term that refers to feather removal.

2. The picker removes the feathers on the carcass.

3. The picker is an automated machine that contains rubber finger-like projections that rotate in a circular motion to remove feathers without damaging the carcass.

F. Removal of feet, head, neck, and oil glands

1. Feet are removed at the ankle joints.

2. The head is cut and removed.

3. The neck is cut with machine and esophagus is exposed

G. Evisceration

1. Evisceration refers to the removal of internal organs.

2. The inedible viscera consists of the spleen, esophagus, lungs, intestines, and reproductive organs.

3. The intestines (viscera) are federally inspected for signs of disease or other problems.

i. Identified disease or other problems results in the removal, or condemnation, of the carcass from the processing line.

4. The edible viscera, or giblets, consist of the heart, liver, and gizzard.

i. The giblets are packaged in the carcass or sold separately.

H. Washing the carcass

1. The carcasses are cleaned for microbial and visible concerns. When processing chicken, microbial bacteria such as E.Coli and Salmonella are analyzed.

I. Chilling

1. The carcass temperature must be reduced to prevent microbial growth.

2. The USDA specifies the amount of chilling for specific bird sizes

i. 4 lb broiler: 40 F within 4 hours

ii. 4-8 lb broiler: 40 F within 6 hours

iii. >8 lb broiler: 40 F within 8 hours

3. Submerging the carcass in an ice (chilled water) bath is the most common method of carcass chilling.

4. Carcass can also be chilled by air chilling.

i. Air chilling occurs by passing cold air over the carcass. This is a more expensive process but some consumers are willing to pay more for air chilling.

J. Cut-up and deboning

1. On average, 75-80% of the live animal weight is retained in the carcass.

i. This amount of live weight retained in the carcass is known as the dressing percentage.

2. The carcass can be sold whole, or individual components of carcass can be cut-up for individual sale.

i. Cut-up often times includes removal of the breast, thigh, drumstick, and wings.

3. Deboning refers to the removal of bone from the cut-up meat.

i. Breasts and thighs are commonly deboned.

K. Further processing.

1. The whole carcass or cut-up and deboned pieces may be further processed for added value.

2. Further processing may include forming, curing, smoking, and cooking of products.

i. Forming product requires a change in particle size and often includes the addition of ingredients to add flavor.

ii. Forming product also requires the use of a mold to obtain desired shape.

iii. Formed products include hot dogs, chicken nuggets, or sausage

3. Curing involves the addition of preservatives, often nitrates, to the meat to improve flavor and product shelf-life.

4. Smoking also acts as a preservative while providing additional flavor to the product.

5. Some product may be prepared in a form that is edible without additional preparation and is known as “ready-to-eat”.

L. Storage

1. Poultry meat should be refrigerated at approximately 30 F. Keeping the poultry below 40 F reduces the risk of microbial growth.

2. Refrigeration and freezing does not kill all microbes, some will survive.

(FAO, http://www.uspoultry.org/educationprograms/PandEP_Curriculum/Documents/PDFs/Lesson9/PoultryProcessingver3.pdf)

What equipment is used during processing?

I. Stunning Cabinet

a. Electrical circuit passes through the whole body and delivers sufficient current to render the bird unconscious immediately and lasting until the bird is killed.

II. Automated Knife Blade

a. Cuts the neck and major blood vessels allowing the blood to flow out of the bird. All birds are stunned and insensible to pain prior to entering the automated knife machine.

III. Scalding Tank

a. The purpose is to loosen the feather follicles of the bird so that the picker can remove the feathers.

IV. Picker

a. Soft, rubber projections (“fingers”) are installed throughout the picker to remove all of the feathers so the bird is ready for processing.

V. Pnuematic shears

a. An air powered device used to remove the neck and head

How is a poultry processing plant layout organized to ensure the production of a safe food product?

I. Flow of operations

1. Poultry processing plants are highly organized and mechanized facilities that contain state-of-the-art technology to ensure the safe preparation of poultry meat products.

2. Processed product should travel from the area of highest potential contamination to the lowest potential contamination

II. Personnel traffic flow

1. Personnel traffic flow should be restricted to prevent potential contamination of product.

2. Personnel should be restricted to their routine work area.

III. Separation of raw and ready-to-eat product

1. Ready-to-eat products must be located in a separate facility from raw product in order to prevent potential contamination.

2. Ventilation systems should direct airflow away from cooked products.

What needs to go on a packaging label

1. “Sell By”

i. Product dating not required.

ii. Preferred by stores for dating.

iii. Date used for quality assurance.

iv. Food can still be used if chicken is frozen and the sell by date is expired.

2. Plant Code

i. The plant code traces the facility that produced the product and tracks the product in case of a recall.

3. Grade of Chicken

i. Grade A- best quality (plump, bruise free, no broken bones)

4. Nutritional Facts

i. Serving sizes

ii. Fat, sugar, sodium, and carbohydrate inclusion.

5. “Keep Refrigerated”

6. Following label regulations

i. Follow all claims

• ✓For example: if labeled “Organic”, the bird must have been raised organically and certified organic.

ii. Some labels are misleading

• ✓For example: “No hormones or steroids” – It is illegal to use hormones or steroids in poultry production.

Standards & Compliance

Poultry processing is regulated under the OSHA General Industry standards (29 CFR 1910). Though there are no standards unique to this industry, all aspects of each operation must carefully be evaluated for compliance with appropriate standards.

OSHA has issued several documents that help in determining compliance with particular General Industry Standards.

Follow-up Checklists

Carrying out these suggestions for follow-up will give you a head start on implementing employee involvement, worksite analysis, and hazard control; these are all elements of an effective occupational injury and illness prevention program.

1. Decide the scope of your follow-up. You may choose either an entire processing area, or one or more single tasks within a processing area. (For plant-wide follow-up, select all processing areas individually.)
2. Review the Hazardous Situations and Possible Solutions for the area or task(s) selected. OSHA has chosen the Possible Solutions from those known to be successful in many situations. In some cases, a single Possible Solution may not be enough to completely eliminate a Hazardous Situation.

   (NOTE: Not all of the Possible Solutions suggested are requirements of OSHA regulations. Some solutions are good practices which have been recognized over time to reduce hazards. To determine which actions are required by OSHA standards, consult the Code of Federal Regulations, 29 CFR Parts 1900 through 1928.)

3. Print out one or more follow-up checklists.
   • Single task - Follow instructions under processing area.
   • Processing areas
     1. Sanitation
     2. Receiving & Killing
     3. Evisceration
     4. Cutting & Deboning
     5. Packout
     6. Warehousing
4. Discuss Possible Solutions with managers and affected employees. Ask for other suggestions for solutions that would work in your plant.
5. Select one or more solutions and develop an action plan to implement them in your workplace.
6. Evaluate the solution to see whether it has eliminated or significantly reduced the Hazardous Situation.

Hazardous Situations and
Possible Solutions

In keeping with OSHA's policy of using plain language, we have attempted to describe theHazardous Situations and Possible Solutionsin words that will be recognized readily by both employers and employees in this industry. OSHA officials and other safety and health professionals may use different terms.

For example:

"Blood on employee" could be referred to as "exposure to contaminants"

"Standing for a long time" could be referred to as "ergonomic fatigue"

"Hands/fingers getting caught by rollers" could be referred to as "unguarded machines"

"Reaching across high and/or wide work surfaces," "repetitive pinch grips," "wrist deflection," and "bending at the waist" could all be referred to as "repetitive ergonomic hazards."

(https://www.osha.gov/SLTC/etools/poultry/standards.html)