Food Safety Workshop at

Zakarison Partnership

Pullman, Washington

October 11, 2008



Topic: Chicken Processing

This workshop begins with a farm tour focusing on the pastured poultry operation. Turkeys and chickens are used to harvest forage during the cover crop phase, and to control weeds during fallow periods.

Portable electric fencing secured with tires, and cement blocks are used to move birds throughout the pastures. This electric mesh keeps them safe from ground predators, baling twine tied randomly overhead discourage birds of prey. Erik’s portable chicken shelters are designed to be moved by one person.

Although the draft animals are not directly related to poultry processing, workshop participants would not let Erik get away with omitting them in the tour. These draft animals, or “solar tractors”, are maintained with fuel produced on the Zakarison farm, including grass, grass hay, grain straw, and oats. To complete the farm power/nutrient cycle, all animal manure is spread back on their farm to enhance soil fertility.

Oxen are in training as part of the “Solar Tractor” Team on the farm. Eric’s experimentation with draft animals has shown him that Oxen are able to negotiate terrain and soil conditions better than horses and mules, however move at a slower pace. Oxen are also less of a financial investment; you can purchase young and raise/train them yourself. On the other hand as a pair of trained mules or horses are quite expensive. In addition to poultry and draft animals, Zakarison Partnership raises sheep using lamas as guardian animals. (not in photo)

The workshop moved onto the Scientific Perspective with Guest Speaker Dr. Karen Killinger, WSU Assistant Professor and Consumer Food Safety Specialist. Karen encouraged everyone to put their “Food Safety Glasses” on as we learn about chicken processing.

Karen also discussed her research on Lactic Acid as an antimicrobial rinse in Mobile Poultry Slaughter Operations, with participation from the audiance!

We now move onto the chicken processing demonstration. Most of this processing system was created with materials and supplies you would find around any farm.

Step #1: The Kill

Eric explains the birds need to be as unstressed as possible before butchering, as it makes a difference in the flavor and texture of the meat.

Chickens are crated the night before they are killed. With no food or water during the night, their gullets are clean, decreasing risk of microbial contamination during the evisceration process.

Eric makes sure the birds are comfortable, with companionship, fresh air and a clean crate.

A demonstration on how to handle birds gently to decrease stress, for example hold bird close to your body.

Killing Cones confine the bird during the kill and bleeding, limiting the amount of damage to meat from thrashing around.

The metal cone in the photo was purchased, and is sized for a chicken. The larger black cones were constructed by Eric with plastic mesh. These are sized for turkeys but can also be used for chickens. Orange traffic cones are also a good size for a turkey killing cone!

Wire secures the chicken’s legs while in the cone at provide additional stability.

Eric identifies the vein to cut to assure the quickest death and most complete bleed.

The objective is to cut the carotid artery and the jugular vein.

Pulling down a bit, to make a clean, smooth, accurate cut, Eric slices the artery.

While the first bird bleeds out, Eric places the second bird in a cone.

The more blood drained out the better.

A gutter is cut and set at an angle under the cones to catch the blood and drain it into a bucket.

Hose is used to wash out the gutter, leaving it clean for the next batch.

Step #2: The Scalder

Eric uncovers the scalder.

The scalder can accommodate up to 4 birds at a time.

The tub is insulated with burlap and blankets.

A pulley system allows Eric to plunge the birds repeatedly.

After plunging birds are put in a bucket and brought to the plucker

Step #3: The Plucker

Constructed from a tub from the inside of a clothes washer, a hose is attached to a tube surrounding the bucket to squirt water on the birds as they are plucked.

Here’s a view of the water squirting.

Plucked chickens.

Chickens are now hung from one leg and hosed down to clean off any bits of feathers or pinfeathers still on the bird.

Hanging birds are ready to move to the Evisceration area.

To reduce the risk of microbial contamination, Eric has two areas set up. Killing, scalding and plucking occur on one side. Evisceration happens on the other side. The ladder with the beam to hang the plucked chickens divides the two sides.

Before proceeding to evisceration, Eric washes his hands.

Hand washing station

Hand washing

Evisceration table has a removable plastic surface for easy cleaning.

All supplies needed are within arm’s reach.

First the feet are cut off

Next the heads

Eric talks about his knife selection. He moves to smaller knives after the large parts have been removed.

Birds have oil gland located on top of the tail.

Eric decreases possible contamination by using the tables’ edge to let organs fall into a bucket, instead of on the table.

Gravity is a great tool for cleaning organs out and eliminating risk of contamination on working surfaces.

Eric can rinse his hands without touching the water hose by placing it in a small wire loop.

One bucket with soapy water, one for organs to save.

Water from work table drains into catch buckets, decreasing possible contamination from water on the ground.

Finished poultry are place in cold metal garbage barrels with ice. Customers pick up their birds on processing day.