Tegel Foods Limited produces an extensive range of poultry products which may contain various potential allergens. These include wheat, soy, milk, and egg, sometimes in combination. This research has two purposes. One was to examine three cleaning stages of processing equipments – Rinse only, Foam and rinse and Sanitise and rinse to validate the efficacy of cleaning required between production runs where the first but not the second product contains the allergen. The allergen chosen to model the cleaning efficacy was gliadin, a protein in wheat. The second aim was to quantify allergenic risk to consumers from inadequately cleaned conveyer surfaces. The commercial motives driving this research were as follows. Cleaning represents a loss in productivity and an increase in consumables costs, and if it can be minimised, this would be advantageous. The requirement to declare the possibility of cross-contamination on retail packaging can potentially adversely affect consumer response, and if these declarations can be avoided then this too would be a commercial advantage. Three approaches were adopted or developed, an ATP bioluminescence test, an ELISA test kit for gliadin, and a Coomassie Blue test to quantify protein given that most allergens are proteins. Fifteen trials were done in the High Care Zone and the Old Further Processing line of the Tegel Henderson Plant production area over a period of nine months. In a typical trial, gliadin values normalised to Uncleaned values fell from 1000 (Uncleaned) arbitrary units, to 60 (Rinse only), to 0.3 (Foam and rinse), to zero (Sanitise and rinse). Parallel ATP tests similarly showed a progressive decrease in values. Compared with Uncleaned, the relative gliadin value was less than the relative ATP value after Foam and rinse in 14 of 14 trials. After Sanitise and rinse the same result was obtained. In the equivalent trials with ATP and Coomassie Blue, after cleaning of Foam and rinse and Sanitise and rinse, the relative ATP values exceeded the relative Coomassie Blue values in four of the five trials. Therefore the considerably cheaper and simpler ATP test is not only an indicator of hygiene but also a good guide to gliadin concentration (gliadin test), and to allergen contamination in general on the basis that allergens are mostly proteins (Coomassie Blue). Modelling of second-product contamination has been done, and was based on knowledge of the absolute gliadin concentration on a typical Uncleaned conveyer surface, as established in the first part of this project. The concept of the worst-case scenario examined the highest possible risk that a sensitive consumer would be exposed to an allergenic dose of gliadin. A pickup efficiency fraction of 0.3 was assumed as an upper limit of contamination from conveyer to the surface of a previously uncontaminated chicken piece. The model showed that the highest concentration of gliadin on the second product would be 6.3 ppm which is below the legislated limit of low-gluten. Information of direct commercial interest to Tegel has been extracted from all these results, and suggestions for future research have been made.

Tegel Foods Limited produces an extensive range of poultry products which may contain various potential allergens. These include wheat, soy, milk, and egg, sometimes in combination. This research has two purposes. One was to examine three cleaning stages of processing equipments – Rinse only, Foam and rinse and Sanitise and rinse to validate the efficacy of cleaning required between production runs where the first but not the second product contains the allergen. The allergen chosen to model the cleaning efficacy was gliadin, a protein in wheat. The second aim was to quantify allergenic risk to consumers from inadequately cleaned conveyer surfaces. The commercial motives driving this research were as follows. Cleaning represents a loss in productivity and an increase in consumables costs, and if it can be minimised, this would be advantageous. The requirement to declare the possibility of cross-contamination on retail packaging can potentially adversely affect consumer response, and if these declarations can be avoided then this too would be a commercial advantage. Three approaches were adopted or developed, an ATP bioluminescence test, an ELISA test kit for gliadin, and a Coomassie Blue test to quantify protein given that most allergens are proteins. Fifteen trials were done in the High Care Zone and the Old Further Processing line of the Tegel Henderson Plant production area over a period of nine months. In a typical trial, gliadin values normalised to Uncleaned values fell from 1000 (Uncleaned) arbitrary units, to 60 (Rinse only), to 0.3 (Foam and rinse), to zero (Sanitise and rinse). Parallel ATP tests similarly showed a progressive decrease in values. Compared with Uncleaned, the relative gliadin value was less than the relative ATP value after Foam and rinse in 14 of 14 trials. After Sanitise and rinse the same result was obtained. In the equivalent trials with ATP and Coomassie Blue, after cleaning of Foam and rinse and Sanitise and rinse, the relative ATP values exceeded the relative Coomassie Blue values in four of the five trials. Therefore the considerably cheaper and simpler ATP test is not only an indicator of hygiene but also a good guide to gliadin concentration (gliadin test), and to allergen contamination in general on the basis that allergens are mostly proteins (Coomassie Blue). Modelling of second-product contamination has been done, and was based on knowledge of the absolute gliadin concentration on a typical Uncleaned conveyer surface, as established in the first part of this project. The concept of the worst-case scenario examined the highest possible risk that a sensitive consumer would be exposed to an allergenic dose of gliadin. A pickup efficiency fraction of 0.3 was assumed as an upper limit of contamination from conveyer to the surface of a previously uncontaminated chicken piece. The model showed that the highest concentration of gliadin on the second product would be 6.3 ppm which is below the legislated limit of low-gluten. Information of direct commercial interest to Tegel has been extracted from all these results, and suggestions for future research have been made.

This study was conducted to optimize the parameters involved in the electronarcosis of market chicken and turkeys. A prototype constant current stunner designed at the Department of Electrical Engineering of Virginia Polytechnic Institute and State University was used. Broilers were electrically stunned with 8, 29 and 50 mA per bird. Turkeys were electrically stunned with 10, 30 and 50 mA per bird. Three weight classes, controlled by age, were used as treatment levels. Broiler males were grown for 36, 43 and 50 days while females were grown for 37, 44 and 51 days. Turkey hens were grown for 84, 98 and 112 days, while toms were grown for 112, 126 and 140 days. Pre-stun levels of 3, 5 and 8 hours of feed and water withdrawal were used for each weight class and sex. The effect of sex, weight and feed and water withdrawal on stunning efficiency, recovery time, blood splatter, bone breakage, color and pH of the breast meat was determined. The experimental unit for each specie, sex, weight and feed withdrawal class used was a "pen" comprised of 10 birds. A total of 130 birds, by gender and specie are used for each repetition. Two repetitions of all experiments were accomplished. A third repetition was done in turkeys, but this time a cooping time of three hours prior to slaughter was added. All data was statistically analyzed with ANOVA and a Box-Behnken response surface design was used to optimize the current for the different experimental variables. Results indicated a significant (p < 0.0001) gender difference in resistance, recovery time and prevalence of defects in both broilers and turkeys. Optimization of the stunning process parameters was not achieved due to inability of the model to express logistic regression equations at the levels used in this study. / Master of Science

Campylobacter jejuni is microaerophilic pathogen and is one of the leading causes of acute diarrhea in the United States. Despite being a microaerophilic pathogen, C. jejuni continues to endure within the domain of food production, especially in poultry processing. In this study, we evaluated the aerotolerance, biofilm forming abilities, and genetic diversity of C. jejuni isolates previously obtained from commercial broiler processing plants. Out of 40 isolates, 25 (62.5%) were aero–sensitive (AS), 10 (25%) were intermediately aerotolerant (IAT), and 5 (12.5%) were hyper aerotolerant (HAT). The isolates belonged to four clonal complexes (CCs) and six sequence types, with the majority of isolates assigned to the CC–353 clonal complexes. Furthermore, the biofilm forming abilities of 12 field C. jejuni isolate on stainless-steel coupons were measured using a crystal violet assay by measuring the optical density (OD600) and viable cell count was enumerated using direct plating. A notable interaction between aerotolerance categories and temperature (P < 0.039) impacting the number of biofilm-attached C. jejuni cells on stainless steel coupons. All isolates had greater counts when incubated at 42ºC compared to room temperature, regardless of oxygen level (P < 0.001). Furthermore, stronger biofilm density was observed at 42°C compared to room temperature, regardless of oxygen level. Eight C. jejuni strains including 3 AS, 3 IAT, and 2 HAT were used to understand the genomic characterization that underlies aerotolerance and biofilm formation in C. jejuni using whole-genome sequencing (WGS). Genes associated with aerotolerance, and biofilms were present in all eight isolates despite the phenotypic differences. The virulence genes associated with Type VI secretion system (T6SS) and VAS effector proteins were unique in aerotolerant isolates. Antimicrobial resistance markers related to antibiotic efflux pumps, beta-lactams, fluoroquinolones, tetracycline, aminoglycosides, and streptothricin were identified. In conclusion, this study elucidates the diverse aerotolerance profiles and genetic characteristics of C. jejuni isolates from poultry processing plants, shedding light on their ability to persist despite environmental stresses. Additionally, the biofilm forming ability at different temperatures emphasizes the importance of targeted interventions to mitigate its impact on food safety.

In poultry plants in the United States, a water chiller is used to chill WOGs (de-feathered birds without giblets). After exiting the chiller these birds are manually transferred from a conveyor belt to shackles for further processing. The current process is less than ideal. The labor pool for jobs such as these is continuing to shrink and labor turnover is a constant problem. The rates of repetitive motion injury reported are high and are continuing to rise. In addition, many poultry producers see this as a bottleneck in the process. Automation has the potential to alleviate these problems. The high variability of this task, cost restrictions, and special design considerations associated with meat handling equipment make automation of this task challenging. Industrial robots have traditionally been limited to tasks with low variability. This task has high variability. They are presented on the conveyor belt in a wide variety of positions and orientations. Most robotic automation systems consist of a commercially available industrial robot, a specialized end effector and a control scheme. The economics of this task prohibit the use of a commercially available industrial robot, as there are no industrial robots on the market that will offer a short enough payback. Robots have not yet been adapted to meat handling processes, and existing robotic designs are not well suited to the task. In designing a low cost, high-speed robot for poultry processing the requirements of the robot are defined and a variety of robot architectures, constructions, and materials are explored. Simple modifications to the existing shackle and conveyor setup to make the task easier for a robot are also explored. After the robot requirements are defined a large group of possible designs are developed. The possible designs are systematically evaluated and/or eliminated until a single design is selected. The forward and reverse kinematics for this robot are developed. A singularity analysis is carried out. A proof of concept model is built. A prototype is modeled and a dynamic analysis of that prototype is carried out. The design is finalized based on the results of the dynamic analysis.

M. Tech. Food Technology / The injection of frozen chicken meat with high levels (m/m) of various brine solutions has been noticed in the South African market. These products are sold with a typical shelf life of one year and the brine solutions used in the commercial factories are being recirculated during normal production. This research project determined the levels (m/m) of brine solutions that contribute to value adding (improved texture and sensory properties) opposed to the levels (m/m) that could result in adulteration (unjustified weight gain/economic adulteration) of frozen chicken meat. The oxidative stability during the one year shelf life as well as the microbiological quality of brine injected frozen chicken meat was also investigated.

Na presente pesquisa foi abordado o conceito de conservação e reúso de água na indústria alimentícia, buscando mostrar a potencialidade de redução do consumo desse recurso. Foram avaliadas questões relacionadas à disponibilidade hídrica nos mananciais superficiais e subterrâneos quanto à sua quantidade e qualidade adequadas para consumo, além da questão legal da cobrança pelo uso da água. Essas provavelmente passarão a ser relevantes num futuro próximo, pressionando as indústrias a buscar meios para minimizar o consumo e gerar menos efluente. O objeto de estudo foi uma indústria de abate de frangos e por tratar-se de setor alimentício, com relação ao reúso de água, a avaliação limitou-se aos usos não potáveis. Embora a prática de reúso de água potável seja permitida em alguns países e existam regulamentações internacionais a respeito, no Brasil o tema ainda é recente sendo que até o momento há somente uma legislação dando diretrizes ao reúso não potável. Inicialmente foi avaliado o uso racional da água, identificando falhas operacionais, propondo melhorias e identificando perdas físicas. Na seqüência foram identificados os setores e os locais com maior consumo de água e geração de efluentes para depois estudar a adoção de técnicas de reúso de água. Dessa metodologia, foi possível obter uma redução global no consumo de água de 14,20% e um aumento na produção de 17,46%. Para aumentar a produção, foi avaliada a adoção de novas fontes de abastecimento. Pelos resultados obtidos, pode-se concluir que o programa de conservação e reúso de água é importante para a economia da indústria e seu desenvolvimento sustentável, e ao meio ambiente por preservar o recurso hídrico. / In this paper the application of water conservation and water reuse concepts in a food industry was studied, focusing the production improvement. It was analyzed issues related to water availability in surface and ground sources with respect to its quantity and quality for potable consumption, in addition to legal issues about charge of water use and effluent discharge, which will probably become very important in the near future, pushing industries for finding ways on how to minimize its water consumption and to generate less wastewater. The study was developed at a poultry processing plant, and because of it is a food industry, water reuse evaluation was limited for non potable applications. Although potable water reuse is allowed in some countries and there are international regulations about this practice, in Brazil this issue is recent, and up to now there is only a very general regulation that deals with non potable water reuse. At first it was evaluated rational water use strategies identifying operational fails, proposing improves and identifying physical losses. It was identified some sectors with high water consumption and wastewater generation, and so that, it also was evaluated practices of water reuse. Results showed a potential for 14.20% in water consumption reduction and a production increase of 17.46%. For more production increase, it was evaluated new water sources. With the results obtained it may be concluded that water conservation and water reuse programs are important for industry economy and its sustainability and for environment by preserving freshwater resources.

Na presente pesquisa foi abordado o conceito de conservação e reúso de água na indústria alimentícia, buscando mostrar a potencialidade de redução do consumo desse recurso. Foram avaliadas questões relacionadas à disponibilidade hídrica nos mananciais superficiais e subterrâneos quanto à sua quantidade e qualidade adequadas para consumo, além da questão legal da cobrança pelo uso da água. Essas provavelmente passarão a ser relevantes num futuro próximo, pressionando as indústrias a buscar meios para minimizar o consumo e gerar menos efluente. O objeto de estudo foi uma indústria de abate de frangos e por tratar-se de setor alimentício, com relação ao reúso de água, a avaliação limitou-se aos usos não potáveis. Embora a prática de reúso de água potável seja permitida em alguns países e existam regulamentações internacionais a respeito, no Brasil o tema ainda é recente sendo que até o momento há somente uma legislação dando diretrizes ao reúso não potável. Inicialmente foi avaliado o uso racional da água, identificando falhas operacionais, propondo melhorias e identificando perdas físicas. Na seqüência foram identificados os setores e os locais com maior consumo de água e geração de efluentes para depois estudar a adoção de técnicas de reúso de água. Dessa metodologia, foi possível obter uma redução global no consumo de água de 14,20% e um aumento na produção de 17,46%. Para aumentar a produção, foi avaliada a adoção de novas fontes de abastecimento. Pelos resultados obtidos, pode-se concluir que o programa de conservação e reúso de água é importante para a economia da indústria e seu desenvolvimento sustentável, e ao meio ambiente por preservar o recurso hídrico. / In this paper the application of water conservation and water reuse concepts in a food industry was studied, focusing the production improvement. It was analyzed issues related to water availability in surface and ground sources with respect to its quantity and quality for potable consumption, in addition to legal issues about charge of water use and effluent discharge, which will probably become very important in the near future, pushing industries for finding ways on how to minimize its water consumption and to generate less wastewater. The study was developed at a poultry processing plant, and because of it is a food industry, water reuse evaluation was limited for non potable applications. Although potable water reuse is allowed in some countries and there are international regulations about this practice, in Brazil this issue is recent, and up to now there is only a very general regulation that deals with non potable water reuse. At first it was evaluated rational water use strategies identifying operational fails, proposing improves and identifying physical losses. It was identified some sectors with high water consumption and wastewater generation, and so that, it also was evaluated practices of water reuse. Results showed a potential for 14.20% in water consumption reduction and a production increase of 17.46%. For more production increase, it was evaluated new water sources. With the results obtained it may be concluded that water conservation and water reuse programs are important for industry economy and its sustainability and for environment by preserving freshwater resources.

This thesis is motivated by practical problems encountered in handling live products in the poultry processing industry, where live birds are manually transferred by human labors. As the task of handling live products is often unpleasant and hazardous, it is an ideal candidate for automation. To reduce the number of configurations and live birds to be tested, this thesis focuses on developing analytical models based on the Lagrange method to predict the effect of mechanical inversion on the shackled bird. Unlike prior research which focused on the effect of different inversion paths on the joint force/torque of a free-falling shackled bird, this thesis research examines the effect of kinematic constraints (designed to support the bird body) on the shackled bird. Unlike free-falling, the imposed kinematic constraints enable the shackled bird to rotate about its center of mass, and thus minimize wing flapping. In this thesis, birds are geometrically approximated as ellipsoids while the lower extremity is modeled as a pair of multi-joint serial manipulators. With the constraint equations formulated into a set of differential algebraic equations, the equations of motion as well as Lagrange multipliers characterizing kinematical constraints are numerically solved for the bird motion, specifically the position, velocity, and orientation and hence the forces and torques of the joints. The dynamic models are verified by comparing simulation results against those obtained using a finite element method. The outcomes of this thesis will provide some intuitive insights essential to design optimization of a live-bird transfer system.

En el presente plan de negocio se pretende determinar la viabilidad de instalar una planta de beneficiado de aves criollas en la provincia de Jaén. Por lo tanto, se requiere abarcar el segmento de consumo de aves criollas en la provincia de Jaén, que está insatisfecha por la deficiencia de condiciones sanitarias e higiene en el proceso de sacrificio y de almacenamiento de la carne de aves criollas, es por ello, que se brinda un servicio con implementación de buenas prácticas de manufactura contando con expertos en beneficiado de aves criollas, teniendo como resultado condiciones salubres e inocuas. La finalidad es presentar un producto con altos estándares de calidad, ayudando así a que nuestros clientes nos prefieran y se fidelicen con nuestra empresa, pero sin dejar de lado el aspecto de las normas de ambientales teniendo una buena disposición de los desperdicios, contribuiremos al cuidado del medio ambiente. / In this business plan, the aim is to determine the feasibility of installing a plant for the benefit of Creole birds in the province of Jaén. Therefore, it is necessary to cover the segment of consumption of Creole birds in the province of Jaén, which is unsatisfied due to the deficiency of sanitary conditions and hygiene in the process of slaughter and storage of the meat of Creole birds, that is why, that a service is provided with the implementation of good manufacturing practices, counting with experts in the benefit of Creole birds, resulting in healthy and innocuous conditions. The purpose is to present a product with high quality standards, thus helping our customers to prefer us and trust with our company, but without neglecting the aspect of environmental regulations having a good disposal of waste, we will contribute to the care environment.