Poultry Processing: The Importance of Live Bird Handling

Proper live bird handling is crucial in any processing plant as it directly impacts animal welfare, product quality, and operational efficiency. In the poultry industry, maintaining the quality of birds from breeding through processing is paramount. After investing significant resources in breeding to achieve optimal bird intake, it is essential to preserve this quality all the way to the consumer. Effective live bird handling systems play a critical role in this process by safeguarding bird welfare, enhancing product quality, and optimizing operational efficiency.

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Current Trends and Challenges in Live Bird Handling

The poultry processing industry is continuously evolving, driven by advancements in technology, changing consumer preferences, and increasing regulatory scrutiny.

One of the most notable trends in poultry processing is the growing emphasis on automation to accommodate higher processing speeds and reduce labour dependence. The degree of automation varies significantly depending on the live bird handling system. Automation begins at the farm with catching devices that gently collect the birds and convey them directly to the transport equipment. In the reception area, full automation is an option, but there are also partially automated systems where only specific tasks, such as destacking, stacking, or equipment wash-down, are automated.

Another significant trend is the shift towards higher animal welfare standards, driven by the desire of both processors and consumers to adopt more humane practices. Beyond its ethical importance, humane handling offers business advantages. Transporting valuable live birds from the farm to the processing plant involves moving them from a safe environment to unfamiliar settings, making animal welfare a critical focus. The conditions during catching, transport, lairage, and processing significantly impact yield and quality, emphasizing the need for careful handling throughout these stages.

Regulatory requirements for live bird handling vary by region but generally emphasize animal welfare, food safety, and worker safety. In the United States, the USDA's Food Safety and Inspection Service oversees the poultry processing industry, enforcing regulations that mandate humane handling and slaughtering practices. The European Union has stringent animal welfare regulations under the European Poultry Welfare Directive, which sets standards from transport to slaughter.

Compliance with these regulations is not optional; it is a legal obligation that can impact a processor's market access. Therefore, staying informed about current and upcoming regulatory changes is crucial for processors to ensure their handling systems meet all necessary standards.

This has led to the development of handling systems designed to reduce stress and injury to birds, such as low-stress transport systems and Controlled Atmosphere Stunning (CAS).

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Sustainability is also a key focus, with processors seeking to reduce their environmental footprint. In the live bird handling area, this includes optimizing water and energy use, minimizing the transportation CO₂ emissions and optimizing the use of each bird by avoiding Death-on-arrivals and bird injuries.

Biosecurity is another critical concern. Effective cleaning and disinfection of transport equipment before picking up the next flock help control the spread of pathogens and minimize the risk of food safety hazards.

Key Drivers for Choosing a Live Bird Handling System

When investing in a new live bird handling system, several operational factors must be considered.

Farm conditions

Farm conditions play a crucial role in this decision. The physical layout and infrastructure of the farm, including the size and design of poultry houses, access roads, and loading areas, will affect the choice of handling equipment. Systems need to be compatible with existing structures to facilitate smooth operation and transport. Large farms typically require systems that can efficiently handle large volumes of birds to minimize stress and handling time.

The availability and skill level of labour on the farm can influence whether a more automated or manual system is appropriate. Automation or fast-loading systems may be more beneficial in areas with labour shortages or where skilled labour is limited.

Transport

Climate and weather conditions, such as temperature, humidity, and seasonal variations, can influence the type of handling system. Heat stress is the biggest challenge during the transport of live birds and one of the main reasons for Death-On-Arrivals. To avoid heat stress, the handling solution must allow for sufficient airflow during transportation and lairage.

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Optimal ventilation and airflow require adequate space and must be balanced with transport efficiency. The goal is to maximize the use of a truck's loadable surface while ensuring the birds' well-being. Additionally, local road restrictions and conditions must be considered when selecting a suitable transport system. Efficient transport minimizes the carbon footprint and boosts business sustainability.

Several factors impact the final decision on live bird transportation:

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Reception

Once the birds arrive at the slaughter plant, the reception system must effectively and gently manage the flow of birds to the shacklers, ensuring a steady feed to the slaughter line regardless of the line speed. Large drawers are particularly effective for feeding high-speed lines, as they accommodate greater volumes while maintaining gentle handling to minimize stress and injury to the birds.

Biosecurity

Farms with stringent biosecurity requirements will need handling systems that support effective sanitation and minimize the risk of pathogen transmission. This includes transport equipment that is designed for easy and efficient wash-down and efficient washing and disinfection equipment in the reception area. Key design features should enable quick cleaning and maintenance to ensure hygiene and reduce downtime.

Budget

Budget constraints and cost-effectiveness are crucial factors in selecting a handling system. Processors must balance the initial investment with potential long-term benefits, such as improved efficiency, fewer Death-on-Arrivals, enhanced product quality, and reduced labour costs or dependency.

Scalability

As operations expand, the ability to adapt to higher processing volumes and future growth becomes increasingly important. A modular and scalable handling system enables poultry processors to upgrade throughput and increase cleaning time seamlessly, without significant disruptions or major equipment overhauls, provided the reception area has adequate space. It's essential to consider future expansion possibilities when designing the plant layout to ensure long-term adaptability and efficiency.

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Choosing the Right Provider

Different farm, legal, and market conditions necessitate varying handling requirements and levels of automation in poultry processing. To meet these diverse needs, BAADER offers crate handling and module/drawer solutions in a variety of modular layout options. These solutions are designed to adapt to specific operational requirements, ensuring flexibility and efficiency in handling processes.

Our live bird handling specialists provide processing audits to effectively analyse current and future challenges, helping processors design reception layouts that meet market demands. With over 80 years of proven expertise in handling live birds, we offer solutions supported by both global and local services to ensure equipment operates smoothly and efficiently.

Visit https://poultry.baader.com/live-bird-handling to learn more about the BAADER live bird handling solutions.