A DEVICE. APPARATUS AND METHOD FOR POULTRY PROCESSING

Field of the Invention

The present invention relates to the field of poultry processing, particularly to deboning and kneecapping of poultry meat.

Background of the Invention

In poultry processing and preparation it is desirable to prepare poultry meat which is clean of bones. The process of removing the meat from the bone is known as deboning. The parts of the poultry which are deboned are the breast , thigh and leg (also known as "drum stick"). Various machines are known for deboning. For Example U.S. 6,027,404 discloses a machine for deboning poultry thighs. Additonal machines also exist for deboning poultry thighs, however, all the processes and machines known in the art provide deboned poultry thigh meat wherein the kneecap is attached to the meat. Said kneecap is removed manually and there are no known mechanized means for removing the kneecap. Manual removal of the kneecap is labor intensive in that it requires people to manually remove each and every kneecap, which is also time consuming. Thus, whereas the deboning of the poultry thigh may be carried out by a machine at a relatively rapid rate, the step of manual kneecap removal impedes the rate of the total process of obtaining the deboned meat. Furthermore, when manual removal of the kneecap is not carried out properly, meat may also be removed with the kneecap, hence resulting in unnecessary loss of meat.

Accordingly, there is a long felt need for mechanized means for kneecap removal from deboned poultry meat and a method for kneecap removal from poultry meat which overcomes the shortcomings of the prior art.

It is therefore an objective of the present invention to provide an apparatus, device and method for removing the kneecap from deboned poultry meat.

Other objects of the invention will become apparent as the description proceeds.

Summary of the Invention

The present invention provides a device for removing the kneecap from deboned poultry meat comprising of an elongated plunger and an elongated hollow casing having a first and second opening into which the plunger fits such that there is a gap between the plunger and the inner surface of said casing.

According to a further aspect of the present invention there is provided an apparatus for removing the kneecap from deboned poultry meat comprising of at least one kneecap- removing device of the present invention, wherein the plunger moves in and out of the casing by manual or mechanical means.

According to a further aspect of the present invention there is provided a method for removing the kneecap from deboned poultry meat by employing the device of the present invention, comprising of the following steps: a) Positioning the deboned poultry meat over the first opening of the casing such that the kneecap is positioned over said opening of the casing and the plunger is positioned in line with said opening and kneecap, b) Pushing the plunger through the casing, while pushing the kneecap through the casing, thus severing the kneecap from the deboned poultry meat.

Description of the Drawings

Fig. I - A side view of the device.

Fig. II - A side view of the device wherein the plunger is inserted in the casing.

Fig. HI - A top view of a circular configuration of an apparatus for kneecap removal.

Fig. IV - A isometric view of a circular configuration of an apparatus for kneecap removal.

Fig. V- A schematic depiction of the method of kneecapping.

Fig. VT - A top view of the plunger and casing

Detailed Description of a Preferred Embodiment of the Invention

The following description is illustrative of embodiments of the invention with reference to the figures. The following description is not to be construed as limiting, it being understood that the skilled person may carry out many obvious variations to the invention.

The present invention provides a device apparatus and method for removing the kneecap from deboned poultry meat such that the severing of the kneecap is carried out rapidly compared to manual removal and is severed in a manner in which less meat is lost compared to manual removal. Throughout the description the term poultry refers to any type of bird which is slaughtered and processed for consumption, non-limiting examples being chickens, turkeys, ducks and geese.

The device of the present invention (also referred to throughout the specification as "kneecap-removing device") comprises of an elongated plunger (1) and an elongated hollow casing (2) having a first (3) and second (4) opening into which the plunger (1) fits such that there is a gap (9) between the plunger (1) and the inner surface of said casing

(2). Said gap (9) allows for parts of the meat and tissue surrounding the kneecap to be caught in said gap (9) while the plunger (1) is pushed through the casing (2). Thus, continuing the motion of the plunger (1) will result in severing the kneecap (5) from the meat (6) and tissue surrounding said kneecap (5). Said gap is of a size suitable for the tissue surrounding the kneecap to become lodged in the gap while the plunger is pushed through the casing. According to a particular non-limiting embodiment of the invention, the size of said gap is in the range of about 0.3mm for small species to about 1.5mm for large pieces of deboned meat. Said plunger (1) and casing (2) can be constructed of the same or different materials. Non-limiting examples of such materials include metal, metal

alloys, composites, polymeric materials, synthetic and natural rubber, silicone based materials. The plunger (1) and the casing (2) may be shaped in various shapes, preferably cylinder shape. The size of the cross section of the plunger (1) and casing (2) are adjusted to suit the type of poultry meat which is processed and the size of the kneecap to be removed, and can be determined by a skilled artisan. According to non-limiting examples, the cross section of a plunger and casing intended for use on chicken meat are such that the plunger for chickens has a cross section size of about 16-22mm and the casing has an inner cross section 0.2-0.5mm larger then the cross section of the plunger.

According to an optional embodiment of said device, a table (10) is attached around the first opening (3) of the casing, such that said piece of deboned meat intended for kneecap removal may be set on said table (10).

According to a further optional embodiment said second opening (4) is equipped with a blade which is intended for scraping the severed kneecap from the plunger (1).

According to a ftirther aspect of the present invention there is provided an apparatus for removing the kneecap from deboned poultry meat comprising of at least one kneecap- removing device (S), wherein the plunger (1) moves in and out of the casing (2) by manual or mechanical means. The motion of the plunger (1) in and out of the casing (1) may be created by relative motion of the plunger (1) and casing (2) which can occur by one of the following mechanisms: The plunger is stationary and the casing moves; the casing is stationary and the plunger moves; or both plunger and casing move. According to a particular embodiment of the present invention the casing (2) is stationary and the plunger (1) is pushed in and out of the casing (2) by means of a lever which is connected to the plunger (1).

According to a further particular embodiment of the present invention the casing (2) is moving while the plunger (1) is stationary. According to a further embodiment both the plunger (1) and casing (2) move relative to each other such that the plunger (1) moves in and out of the casing (2).

In yet a further preferred embodiment of the present apparatus several kneecap-removing devices (8) are assembled in an array, wherein said array may be circular (Fig. HI, IV) or linear. The motion of the kneecap-removing devices (S) may be such that when the kneecap-removing device (8) reaches a certain point in the apparatus motion between the plunger (1) and casing (2) is generated such that the plunger (1) moves in and out of the casing (2). Said motion can be generated by a motor which directly moves the plunger (1) or casing (2) or both. The motion between the plunger (1) and casing can be created by various means methods as may be appreciated by the skilled artisan. Non-limiting examples of such methods also include geometrical design of the apparatus which create a track of motion which causes the plunger (1) to move in and out of the casing (2).

According to a specific embodiment of the apparatus of the present invention, three or more devices (8) are arranged in a circular array of devices such that rotation of the array positions a device (8) before a working station where a worker stands and positions a piece of deboned meat in the device or removes an already kneecapped piece of meat from the device. Circular motion of the array of devices (8) results in relative motion of the plunger (1) in and out of the casing (2), such that when the device reaches the position before the work station the plunger is out of the casing and when it roates away from the work station, there is motion of the plunger (1) in and out of the casing (2) such that when said device (8) arrives again at the work station, the plunger (1) is out of the casing (2) and the kneecap (5) has been severed from the meat.

According to a further aspect of the present invention there is provided a method for removing the kneecap (5) from deboned poultry meat (6) by employing the kneecap- removing device (8) of the present invention, comprising of the following steps: a) Positioning the deboned poultry meat (6) between the casing (2) and the plunger (1) such that the kneecap (5) is positioned over an opening (3) of the casing (2) of said device (8), b) Pushing the plunger (1) through the casing (2), hence severing the kneecap from the deboned poultry meat.

The severed kneecap then falls through the other opening (4) of the casing (2), the plunger (1) is removed from the casing (2). Fig. V (A) to (C) depicts the operating steps of said device. Fig. V(A) shows the deboned meat (6) positioned between the plunger (1) and the casing (2) wherein the kneecap ( 5) is positioned over the first opening (3). Fig. V(B) shows the lowering of the plunger (1) into the casing (2) such that the kneecap (5) is pushed by the plunger (1) into the casing (2). Fig. V(C) shows the final stage of the method wherein the plunger (1) has exited through the second opening (4) pushing the severed kneecap (Fig. V (C), (5)) through the casing (2).

The present invention presents the following advantages; the kneecap is removed more rapidly and in higher precision than when severed manually. Thus, processing of poultry deboned meat is faster and more efficient. Furthermore, the improved precision brings about less loss of meat. For example, in manual removal of the kneecap from a deboned chicken thigh there is an average weight loss of about 12 grams, wherein according to the present method, utilizing the device and apparatus of the present invention, the average weight loss is about 4 grams. The above mentioned advantages have quite significant financial implications and can result in higher profitability to the poultry industry by improving both efficiency and yield.

While embodiments of the invention have been described by way of illustration, it will be apparent that the invention may be carried out with many modifications, variations and adaptations, without departing from its spirit or exceeding the scope of the claims.