Poultry Meat Processing Edited by Alan R. Sams, Ph.D. Department of Poultry Science Texas A&M University CRC Press Boca Raton London New York Washington, D.C. Published in 2001 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2001 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S. Government works Printed in the United States of America on acid-free paper 109876543 International Standard Book Number-10: 0-8493-0120-3 (Hardcover) International Standard Book Number-13: 978-0-8493-0120-9 (Hardcover) Library of Congress Card Number 00-046763 This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. 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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data Poultry meat processing / Edited by Alan R. Sams p. cm. Includes bibliographical references and index. ISBN 0-8493-0120-3. 1. Poultry—Processing. I. Title. TS1968 .S36 2001 664′.93—dc21 00-046763 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com Taylor & Francis Group and the CRC Press Web site at is the Academic Division of T&F Informa plc. http://www.crcpress.com 920024_CRC12_0329_fm 11/14/00 5:07 PM Page iii Dedication This book is dedicated to the memories of Dr. Pam Hargis and Dr. Doug Janky, two individuals who each had a profound and lasting impact on the poultry, food, and nutritional sciences, as well as the people involved in them. This page intentionally left blank 920024_CRC12_0329_fm 11/14/00 5:07 PM Page v Preface This book is the product of some of the best poultry and food scientists in the world today. Its concept was born from the need for a good instructional textbook in the poultry pro- cessing and product quality courses taught by many of the contributors. The text is an instructional and not necessarily exhaustive review of the scientific literature in each of its component areas. In addition to its teaching use, this book will also be a useful reference for academic researchers, industry personnel, and extension specialists/agents seeking further knowledge. Most of the contributors are active participants in the S-292 USDA Multi-State Research Project, and the collaborative relationships fostered by this project have made this book possible. I thank the contributors for their time and meaningful input. I am also deeply indebted to Mrs. Elizabeth Hirschler for her excellent technical and creative assistance, without which this book would not have been possible. Alan R. Sams, Ph.D. Editor v This page intentionally left blank 920024_CRC12_0329_fm 11/14/00 5:07 PM Page vii Contributors James C. Acton Paul L. Dawson Department of Food Science Department of Food Science Clemson University Clemson University Clemson, SC Clemson, SC Sacit F. Bilgili Glenn W. Froning Department of Poultry Science Department of Food Science Auburn University and Technology Auburn, AL University of Nebraska Lincoln, NE J. Allen Byrd Southern Plains Agricultural Research Billy M. Hargis Center Departments of Veterinary Pathobiology College Station, TX and Poultry Science Texas A&M University David J. Caldwell College Station, TX Departments of Veterinary Pathobiology and Poultry Science Jimmy T. Keeton Texas A&M University Department of Animal Science College Station, TX Texas A&M University College Station, TX Muhammad Chaudry Islamic Food and Nutrition Council Chicago, IL Brenda G. Lyon U.S. Department of Agriculture Donald E. Conner Agricultural Research Service Department of Poultry Science Russell Research Center Auburn University Athens, GA Auburn, AL Clyde E. Lyon Michael A. Davis U.S. Department of Agriculture Department of Poultry Science Agricultural Research Service Auburn University Russell Research Center Auburn, AL Athens, GA vii 920024_CRC12_0329_fm 11/14/00 5:07 PM Page viii viii Contributors Shelly R. McKee Scott M. Russell Department of Food Science Department of Poultry Science and Technology University of Georgia University of Nebraska Athens, GA Lincoln, NE Alan R. Sams William C. Merka Department of Poultry Science Department of Poultry Science Texas A&M University University of Georgia College Station, TX Athens, GA Denise M. Smith Department of Food Science Julie K. Northcutt and Toxicology Department of Poultry Science University of Idaho University of Georgia Moscow, ID Athens, GA Doug P. Smith Casey M. Owens Department of Poultry Science Department of Poultry Science University of Georgia University of Arkansas Athens, GA Fayetteville, AR Lei Zhang Joe M. Regenstein Department of Poultry Science Cornell University Auburn University Ithaca, NY Auburn, AL 920024_CRC12_0329_fm 11/14/00 5:07 PM Page ix Contents Preface . v Chapter 1 Introduction to Poultry Meat Processing . 1 Alan R. Sams Chapter 2 Preslaughter Factors Affecting Poultry Meat Quality . 5 Julie K. Northcutt Chapter 3 First Processing: Slaughter through Chilling . 19 Alan R. Sams Chapter 4 Second Processing: Parts, Deboning, and Portion Control . 35 Alan R. Sams Chapter 5 Poultry Meat Inspection and Grading . 47 Sacit F. Bilgili Chapter 6 Packaging . 73 Paul L. Dawson Chapter 7 Meat Quality: Sensory and Instrumental Evaluations . 97 Brenda G. Lyon and Clyde E. Lyon Chapter 8 Microbiological Pathogens: Live Poultry Considerations . 121 Billy M. Hargis, David J. Caldwell, and J. Allen Byrd Chapter 9 Poultry-Borne Pathogens: Plant Considerations . 137 Donald E. Conner, Michael A. Davis, and Lei Zhang Chapter 10 Spoilage Bacteria Associated with Poultry . 159 Scott M. Russell Chapter 11 Functional Properties of Muscle Proteins in Processed Poultry Products . 181 Denise M. Smith Chapter 12 Formed and Emulsion Products . 195 Jimmy T. Keeton Chapter 13 Coated Poultry Products . 227 Casey M. Owens Chapter 14 Mechanical Separation of Poultry Meat and Its Use in Products . 243 Glenn W. Froning and Shelly R. McKee Chapter 15 Marination, Cooking, and Curing of Poultry Products . 257 Doug P. Smith and James C. Acton Chapter 16 A Brief Introduction to Some of the Practical Aspects of the Kosher and Halal Laws for the Poultry Industry . 281 Joe M. Regenstein and Muhammad Chaudry ix 920024_CRC12_0329_fm 11/14/00 5:07 PM Page x xChapter number, Chapter title Poultry Meat ProcessingContentsx Chapter 17 Processing Water and Wastewater . 301 William C. Merka Chapter 18 Quality Assurance and Process Control . 311 Doug P. Smith Index . 327 920024_CRC12_0329_ch01 11/13/00 9:30 AM Page 1 chapter one Introduction to poultry meat processing Alan R. Sams Poultry processing is a complex combination of biology, chemistry, engineering, market- ing, and economics. While producing human food is the main goal of poultry processing, related fields include waste management, non-food uses of poultry, and pet/livestock feeds. When considering the global marketplace, poultry refers to any domesticated avian species, and poultry products can range from a slaughtered carcass to a highly refined product such as a frankfurter or nugget. However, because they dominate the market, chicken and turkeys will be the focus of this book. The common classes of commercial poul- try are summarized in Table 1.1. The reader should remember that specific numeric processing conditions in this book are for illustrative purposes and that these conditions may vary between processors. The aims of this book are both to instruct the user in what steps/conditions are used for processing poultry and to explain why things are done that way. This approach will enable the reader to evaluate problem situations and develop pos- sible solutions. Commercial poultry is extremely uniform in appearance and composition. Tightly managed breeding, incubation, rearing, and nutritional regimes have created a bird that is a virtual copy of its siblings. This uniformity has allowed poultry processing plants to develop into highly automated facilities with an efficiency that is unmatched by other live- stock processors. With line speeds of 70 to 140 chickens/min, uniformity, automation, and efficiency are recurring themes and have been keys to the success of poultry processing. Table 1.1 Common Classes of Commercial Poultry Class of poultry Age (weeks) Specifications Cornish hen chicken Ͻ4 Ն25% Cornish and Ͻ2.0 lb processed Broiler or fryer chicken 6–8 Most common commercial chicken Roaster chicken 8–10 Large bird for whole holiday meals or boneless meat Stewing hen chicken 52ϩ Breeder hen that no longer produces eggs at an economical rate Fryer turkey 9–16 Young turkey usually sold whole Roaster or young hen/tom 16–24 Most common form of turkey; sold whole, turkey in parts, or as boneless meat Hen/tom turkey 52ϩ Breeder bird that no longer reproduces at an economical rate 0-8493-0120-3/01/$0.00+$.50 © 2001 by CRC Press LLC 1 920024_CRC12_0329_ch01 11/13/00 9:30 AM Page 2 2 Poultry meat processing Figure 1.1 Diagram of the material flow between the components of a vertically integrated poultry company.