Background

[0001] Typical methods of processing carcasses for human consumption include methods of reducing carcass pathogens such as Salmonella and Campylobacter on surfaces of the carcasses. Introducing an antimicrobial solution to the carcass is one way of removing carcass pathogens. Two methods used to introduce an antimicrobial solution to a carcass are with the use of a dip tank and with the use of a rinse cabinet. Most rinse cabinets provide mists of antimicrobial solution that covers the carcass. Depending on the carcass species; its effectiveness is limited where pathogens are located in creases or folds of a carcass being sanitized. With the dip tank method carcasses are fully immersed in the antimicrobial solution in a dip tank. This method is usually more effective than a rinse cabinet however solution received in the cavity can lead to waist of the solution which in turn leads increased processing costs. Moreover, with some processing techniques, the use of a dip tank may lead to unwanted results. For example, kosher processes where chicken carcasses are not scaled with warm water to facilitate de-feathering but are directly defethered, abrasions of skin occur. These abrasions will cause pockets than can be filled with water or antimicrobial solutions. Unacceptable organoleptic issues arise from pockets of solution that form because of the abrasions with the dip tank method. The issues arising include prolonged efficacy from these pockets of the antimicrobials causing organoleptic effects.

[0002] For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an improved system and method of processing carcasses.

Summary of Invention

[0003] The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention. [0004] In one embodiment, a method of cleaning carcasses for consumption is provided. The method includes passing carcasses through a tank; showering the carcasses with antimicrobial solution; collecting the antimicrobial solution in the tank under the carcasses. Filtering the collected antimicrobial solution in the tank; mixing the filtered antimicrobial solution with new antimicrobial solution and providing the mixed antimicrobial solution to shower the carcasses with the antimicrobial solution.

Brief Description of the Drawings

[0005] The present invention can be more easily understood and further advantages and uses thereof more readily apparent, when considered in view of the detailed description and the following figures in which:

[0006] Figure 1 is side view of a carcass processing system of one embodiment of the present invention;

[0007] Figure 2 is a side perspective view of a filtering system of one embodiment of the present invention; and

[0008] Figure 3 is a flow diagram of one method of implementing a carcass processing system of one embodiment of the present invention.

[0009] In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text.

Detailed Description

[0010] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.

[0011] Embodiments of the present invention provide a method and system of processing carcasses such as but not limited to fowl (e.g. such as chicken and turkey carcasses). The system provides a method of reusing an antimicrobial solution used to decontaminate surfaces of carcasses. Moreover, embodiments, carcasses are showered with antimicrobial solution with a sufficient force to penetrate creases or folds on the outside surface of the carcass. The antimicrobial solution may include but is not limited to acidified sodium chlorite (such a Sanova ®) or peroxyacetic acids (such as Inspexx ™).

[0012] Referring to Figure 1, a carcass processing system 100 of one embodiment is illustrated. As illustrated, the system 100 includes a tank 102 such as a dip tank. However, the tank 102 is not used to dip the entire carcass in a solution as a traditional dip tank would be used. In one embodiment, the carcasses 112 are not immersed at all in a buffer 118 (used solution 118). In another embodiment, an upper part (neck) of a carcass 112 is dipped in the used solution 118 as illustrated in Figure 1. In this embodiment, during ascend of the carcasses 112 into the cabinet, the shackles 108 (connectors 118) may become unstable resulting in the release of the carcasses 112 into the dip tank 102. In order to prevent this, the level of buffer 118 is raised to a level that contacts a portion of the carcasses 112 for stabilization of forward/backward movement. The embodiment used depends on process methodology and shackle type 108.

[0013] In the embodiment of Figure 1, the carcasses 112 are coupled to a conveyer line 106 via connectors 108. In particular, in this embodiment, a leg of each carcass 112 is coupled to an associated connector 108. The conveyer line 106 moves the carcasses 112 through the tank 102. As the carcasses 112 are moved through the tank 102, antimicrobial solution 118 is showered on them via pair of pipes 114 and 116. As illustrated the first pipe 114 and second pipe 116 run parallel to conveyer line 106 such that carcasses 112 are position between the first and second pipes 114 and 116. Fluid dispensing apertures 115 are located in the respective first and second pipes 114 and 116 to direct a flow of the solution 117 flowing through the pipes 114 and 116 on the carcasses 112. A pressure of the solution 117 in the pipes is selected to force the solution out of the dispensing apertures 115 and open up creases or folds on the surface of the carcass 112 so that the solution 117 penetrates all surface areas of each carcass 112. The pressure used is set at a plant specific level (depends on scalding technique, scalding temperature and the accessibility of follicles of the carcasses 112. In one embodiment the minimum pressure is at least 4.5 bar (65 Psi). In at least one embodiment, the pipes 114 and 116 (or bars) are located above the carcasses and the fluid dispensing apertures are directed down towards the carcasses 112 to effectively rinse each carcass. Further in one embodiment a stabilizing rail 111 is used to stabilize the carcasses as they pass through the tank 102.

[0014] The tank 102 is used to collect used solution 118. The length of the tank 102 depends on the line speed. In one embodiment, the tank should be long enough to provide 15 seconds of conveyor distance. The tank 102 is preferably but not necessarily straight. The form of the tank depends on the availability of space and conveyor speed. In one embodiment, a select depth of the used solution 118 is maintained in the tank 102. The select depth in the embodiment illustrated in Figure 1, allows at least the neck portion of carcasses 112 to be submerged in the used solution 118 as the carcasses 112 passes through the tank 102. Having a neck portion of a carcass 112 submerged in the used solution 118 further stabilizes the carcass as it moves through the tank 102 as discussed above. This embodiment also enhancing the effectiveness of the flows of solution 117 on the carcasses 112. In one embodiment, an over flow port 150 is used to remove excess used solution 118. The used solution 118 collected in the bottom of the tank 102 is pumped out via pump 102 through hose 122. The solution is pumped into a filtering system 200. The filtering system 200 in this embodiment includes a rotating drum 128 having a plurality of filtering apertures 103. The used solution 118 is pumped from dip tank 102 and sprayed onto the drum 128 with nozzles 126. In one embodiment, the nozzles 126 have a diameter between 3-5 mm. The drum 128 filters out large particles of organic residue (such as fat and protein) which are collected in the rinse cabinet 104. The filtered solution is collected and passed on to a mixing pump 138 via hose 136. The mixing pump 103 includes a fresh solution inlet 140 that is connected to receive new solution. The mixing pump 138 mixes the filtered solution with new solution and pumps the mixture into pipes 114 and 116 at a select pressure. Hence, in embodiments, the filtered solution 117 is reused by collecting the used solution 118, filtering it and then combining it with new solution.

[0015] Figure 2 illustrates a side-perspective view of filtering system 200 of one embodiment. As illustrated, the filtering system 200 includes a filter holding tank 104 in which the rotating drum 128 is received. As discussed above, the rotating drum 128 has a plurality of filtering apertures 130 that filter the used solution 118. In particular, the used solution 118 is pumped from dip tank 102 through filter pipe 124 and out nozzles 126 onto an outer surface 210 of the rotating drum 128. A splash housing 206 is used to prevent the used solution 118 from splashing beyond the filtering system 200. The filtered solution 117 that passes through the filtering apertures 130 is directed into a collecting hose 136 via directing plate 204 that is positioned inside the rotating drum 128. Particles 202 in the used solution 118 that do not pass through the filtering apertures 103 are first collected on the outside surface 210 of the rotating drum 128 then transferred to the holding tank 104 as the rotating drum 128 rotates. The waist and particles 202 in the holding tank 104 are removed via removal port 134 that is coupled to removal tube 212. Although, the embodiments illustrated in Figures 1 and 2 show the filtering system 200 outside of the dip tank 102, in other embodiments, the filter system 200 is retained inside the dip tank 102. Hence, in one embodiment, filter system 200 is incorporated in the dip tank 200.

[0016] Referring to Figure 3, a carcass process flow diagram 300 of one embodiment is illustrated. As illustrated, the process begins by passing carcasses 112 through a tank 102 (302). As the carcasses 112 pass through the tank 102, flows of antimicrobial solution are directed on the carcasses 112 (304). As described above, in one embodiment, the flows of solution shower the carcasses 112. The flow of solution 118 is collected in the tank 102 under carcasses 112 (306). In one embodiment, the level of solution 118 collected is maintained at a height that allows for neck portions of the carcasses 112 to be submerged in the solution 118. This provides stability to the carcasses 112 as they pass through the tank 102 and are exposed to the flows of the solution 118. The collected used solution 118 is pumped to a filtering system 200 (308). Hence, in embodiments that maintain the level of solution in the tank 102 at a select level, the rate upon which the used solution 118 is pumped out of the tank 102 is matched with the rate of the filtered solution 117 showered on the carcasses. Moreover, as discussed above in one embodiment an additional over flow port 150 is used to ensure that not much used solution 118 is maintained in the drip tank 102. The collected used solution 118 is then filtered to remove particles (310). The filtering removes particles that would clog the fluid dispensing apertures 115 that deliver the shower of solution 117 to the carcasses 112. The filtered solution is then combined with new solution (312). The combined solution 117 is then directed onto the carcasses 112 in step (304).

[0017] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.