BACKGROUND OF THE DISCLOSURE

[0001] The present disclosure relates generally to a method for processing meat, and more specifically a method for butchering a cattle carcass.

[0002] When an animal carcass, such as a cow carcass, is prepared for butchering, typically the carcass is hung by two limbs, the breastbone is cut, the internal organs are removed, and the carcass is split into two halves and cooled. Splitting the carcass both increases the rate of cooling the carcass, which is often necessary to reduce the growth of pathogens, and makes it easier to handle the carcass for butchering. However, this method often causes meat contamination through spinal cord exposure. Further, requiring the carcass be cooled prior to removing primal cuts makes the meat harder and more difficult to debone and puts more stress on butchers. This can result in hand injuries such as carpel tunnel syndrome.

[0003] Once the carcass is prepared, all primal cuts are removed. There are multiple methods and devices for supporting and positioning a carcass during this process. Such devices might include, hooks, rib spreaders, and hanging devices, to name a few. For all of these methods, the backbone on the carcass is split as detailed above.

[0004] Splitting the backbone may cause contamination through spinal cord exposure. To counteract this, time and money is spent on decontamination methods to ensure that the resultant beef is safe to eat. The results of these methods are often not satisfactory.

[0005] Thus, there is a need for a carcass butchering method that removes the risks associated with splitting the backbone of a carcass and increases the speed at which a carcass is cooled to minimize the potential of harmful bacteria.

SUMMARY OF THE DISCLOSURE

[0006] Accordingly, it is an object of the present disclosure to provide a method for processing beef, including the steps of preparing a beef carcass for butchering, reducing the carcass temperature by 20 degrees Fahrenheit, removing primal cuts from the carcass, packaging and cooling the primal cuts to 32-34 degrees Fahrenheit, and preparing the packaged primal cuts for distribution. To prepare the beef carcass, the head of the cattle is removed and the carcass is eviscerated. The carcass is then cooled for approximately three to four hours to lower its temperature to 75-85 degrees in preparation of removing the primal cuts. The carcass is then arranged on a butchering device such as the device disclosed in the Hendrix U.S. Patent No. 11129391, and the primal cuts are removed. The cuts are then placed in a cooler for approximately 60 minutes to reduce their temperature to 32-34 degrees Fahrenheit. The entire beef processing method, from kill floor to packaging, can be completed within 24 hours.

[0007] In one embodiment, preparing a beef carcass for butchering further includes scoring the carcass back without cutting through the carcass backbone or spinal cord, hanging the carcass by a carcass hind portion, removing the hind legs, inserting a hanging device through an opening in the carcass and extending the device through an opening in the carcass neck, inverting the carcass to hang from the hanging device, and removing the forelegs from the carcass.

[0008] In another embodiment, at least one of the cooling steps is performed in an environment having a humidity of 84-92% to minimize beef shrinkage.

BRIEF DESCRIPTION OF THE FIGURES

[0009] Other objects and advantages of the disclosure will become apparent from a study of the following specification when viewed in the light of the accompanying drawing, in which:

[0010] Fig. 1 is a flow chart showing steps for processing beef according to the present disclosure;

[0011] Fig. 2 is a front perspective view of a beef carcass hanging from its hind legs;

[0012] Fig. 3 is a top perspective view of a beef carcass hanging from its hind legs with a carcass hanging device inserted in a cavity of the carcass;

[0013] Fig. 4 is a front perspective views of a beef carcass hanging from a hind portion;

[0014] Fig. 5 is a front perspective view of a beef carcass in the process of being inverted according to the present disclosure;

[0015] Fig. 6 is a bottom perspective view of a beef carcass hanging from a carcass hanging device;

[0016] Figs. 7 and 8 are rear and side perspective views, respectively, of a beef carcass hanging from a carcass hanging device; [0017] Fig. 9 is a rear perspective view of a beef carcass that has been scored down its back;

[0018] Fig. 10 is a perspective view of a beef carcass arranged on a butchering device;

[0019] Figs. 11 and 12 are front and detailed perspective views, respectively, of a first embodiment of an apparatus for supporting and maneuvering an animal carcass according to the present disclosure;

[0020] Fig. 13 is a perspective view with a cutaway portion of the frame and carcass holding device of Figs. 11 and 12.

[0021] Fig. 14 is perspective cutaway view of a portion of the carcass holding device of Figs. 11- 13;

[0022] Fig. 15 is a perspective view of an animal carcass secured with the apparatus of the present disclosure;

[0023] Figs. 16 and 17 are front and detailed perspective views of a second embodiment of an apparatus for supporting and maneuvering an animal carcass according to the present disclosure;

[0024] Figs. 18-20 are perspective views of spreading plates in different positions, respectively, according to the embodiment of Figs. 16 and 17;

[0025] Fig. 21 is a perspective view of the carcass holding device and rotation device from Fig. 17 with the carcass stabilizer removed;

[0026] Fig. 22 is a front view of the inner shaft of the carcass stabilizer shown in Fig. 21; and

[0027] Fig. 23 is a perspective view of a portion of the carcass stabilizer shown in Fig. 21

DETAILED DESCRIPTION

[0028] The present disclosure relates to a method for processing beef. Referring to Fig. 1, the method includes first removing the cattle head and then eviscerating the carcass so that all internal organs and potential contaminates are separated from the meat that will be processed. Unlike with other butchering methods, the sternum is not split prior to evisceration. The head and organs are then inspected to ensure the cattle carcass is acceptable for human consumption. If it is acceptable, the butchering process continues. At this time, it is expected that the internal temperature of the carcass will be 102-104 degrees Fahrenheit, though that range may vary. [0029] Referring now to Fig. 2, to butcher the carcass according to the present method, the carcass 202 is first hung by its hind portion 204 and then the hind legs 206 are removed. Figs. 7 and 8 show the carcass being supported by a hanging device 208, such as the one disclosed in the Hendrix ‘391 Patent. Figs. 3 and 4 show the device as it is inserted through a carcass opening 210, extended through a carcass neck opening 212, and hung from a support structure 214, such as a beam. The carcass is then inverted, as shown in Fig. 5, so that it hangs from and is supported by the device 208. Fig. 6 shows the device fully inserted into the carcass and contacting an inner surface 216 of the carcass.

[0030] Referring again to Figs. 7 and 8, once the carcass 202 is inverted, it is supported by the hanging device 208 connected with a support structure 214. At this time, the forelegs 218 are removed from the carcass and the carcass is scored down its backbone, which is shown in Fig. 9.

[0031] As further detailed in Fig. 1, the carcass is then cooled for approximately three to four hours to an internal temperature in the range of 75 to 85 degrees Fahrenheit, though temperatures as low as 70 degrees and as high as 90 degrees are acceptable. A standard cooler known in the beef processing industry can be used to reduce the temperature, though as discussed below, the size and environment of the cooler may vary. Once the carcass reaches the desired internal temperature, it is removed from the cooler. The carcass is then ready for removal of all primal cuts. Importantly, unlike with known methods for butchering cattle, the backbone is never cut and the carcass is not split into two halves, thus removing the potential for contamination that arises when cutting through the spinal cord.

[0032] Preferably, the cooling process takes place in an environment having a relative humidity of 84-92%. This, in addition to the shortened three to four hour cooling period, results in beef shrinkage of less than 1% and in some instances as low as half of a percent. This is an important improvement over the industry standard of 2% shrinkage, resulting in more high quality beef.

[0033] Referring now to Fig. 10, the carcass 202 is arranged on a butchering device 220 such as the device described in the Hendrix ‘391 patent, which is used to maneuver the carcass while removing the primal cuts. The apparatus allows for varying the height and position of the carcass, making the butchering process easier on butchers as compared to other known methods and devices. Moreover, the device does not require the back or sternum to be split, again reducing the potential for contamination as a result of such practices. [0034] Referring to Figs. 11-14, the device will be discussed in detail. There is an apparatus 2 which includes a frame 4 and a carcass holding device 6 connected with the frame. The frame 4 includes a linear displacement device 8 and a rotation device 10. The linear displacement device 8 provides linear displacement of the carcass holding device 6 via a piston and air cylinder 12, while the rotation device 10 provides rotation of the carcass holding device via a motor 14 and internal rotatable shaft 16. The linear displacement device 8 is connected with the rotation device 10, and the rotation device connected with the carcass holding device 6 via connection plates 18. The carcass holding device 8 includes a gear assembly 20 arranged within a housing 22 of the device 8, a pair of support arms 24 connected with the gear assembly, and a pair of plates 26 connected with the support arms.

[0035] In operation, the gear assembly 20 displaces the plates 26 between a retracted position in which the plates may be inserted into an animal carcass rib cage and an expanded position wherein the plates engage the rib cage to secure the animal carcass for butchering, as shown in Fig. 15. The linear displacement device 8 provides linear displacement of the carcass holding device 8 to lower or raise a carcass, and the rotation device 10 provides rotation of the carcass holding device 8 to adjust the angle of the carcass. The frame 4 and carcass holding device 6 are controlled via an air actuator valve 28 connected with the apparatus and via switches 30 arranged on the linear displacement device 8. It will be understood by those of skill in the art that other methods of power may be used to provide linear displacement and rotation of the carcass holding device without deviating from the pertinent elements and purpose of the apparatus. For example, as with the hydraulic assembly 132 shown in Fig. 16. Further, linear displacement and rotation may be provided by devices other than the piston and cylinder and/or motor and shaft.

[0036] This device helps with the overall timing of the process discussed herein. Rather than first cooling the carcass, the cow is butchered on the apparatus and cooled after all the beef cuts have been completed. This results in a total butcher to truck time of approximately seven hours, significantly less than the three-day industry standard. Further, the apparatus with spreading plates allows a cow to be butchered without splitting the breastbone and backbone. This reduces time and effort needed to butcher a cow, and also removes the risk of spinal cord contamination. Lastly, by butchering the cow while it is still hot or warm, injuries to those butchering the cow, such as carpal tunnel syndrome, will be reduced because a hot carcass is easier to butcher and debone than a cold carcasses. [0037] Referring now to Figs. 13 and 14, the previously described embodiment of the carcass holding device is shown in detail. The gear assembly 20 includes a worm gear 34 and associated shaft 36 arranged within the device housing 22 that is operated via a motor 38. The first ends 40 of the support arms 24 are pivotally connected with the gear assembly 20 on opposite sides of the worm gear shaft 36. The support arms extend through openings 42 in sides of the housing 22 and connect at a second end 44 with the pair of plates 26. The worm gear 34 is operated via the motor 38 for linear displacement of the support arm first ends 40, resulting in displacement of the spreading plates 26 between retracted and expanded conditions. The plates include spikes 46 arranged near edges of the plates in spaced relation which engage with a carcass when the spreading plates are inserted into the carcass to prevent the carcass from sliding on the spreading plates.

[0038] Referring now to Figs. 16 and 17, a second embodiment of the apparatus 102 is shown. As with the embodiment described above, there is a frame 104 and carcass holding device 106. The frame includes a linear displacement device 108 for linear displacement of the carcass holding device 106 and a rotation device 110 for rotation of the carcass holding device. Rotation via the rotation device, as well as expansion and retraction of the spreading plates 126 is provided by hydraulic assemblies 132. Fig. 6 shows the entire hydraulic assembly 132, including the hydraulic motor 148, hoses 152, gauges 154 and switches 156, connected with a rear end 158 of the rotation device 110 and with the linear displacement device, respectively. Fig. 7 shows the hydraulic motor 148 attached to the bottom end 150 of the carcass holding device. The hydraulic assemblies provide the power necessary to operate the rotation device 110 and carcass holding device 106. For the carcass holding device, the hydraulic motor operates a gear assembly (not shown), causing the spreading plates 126 to retract or expand. The hydraulic assembly attached to the rotation device 110 rotates an internal shaft (not shown), which in turn rotates the carcass holding device that is attached with the rotation device.

[0039] Figs. 18-20 show the spreading plates 126 of the second embodiment in detail. Each plate 126 has a generally rectangular configuration with two angled corner edges 160 located diagonally opposite one another. The edges angle outwardly relative to the back 162 of each plate 126. Each spreading plate 126 has a connection bracket 164 connected to the plate at an approximately ten-degree angle relative to the back 162 of the plate and extending outwardly from the back of the plate. The bracket connects with the second end 144 of the support arms 124. To accommodate the support arms 124 being arranged on opposite sides of the internal shaft, the brackets 164 are arranged at different positions on each plate 126. The angled corner edges 160 provide additional friction between the spreading plates and carcass, reducing the potential of having the carcass move relative to the spreading plates.

[0040] Referring now to Fig. 17 a carcass stabilizer 166 connected with a side wall 168 of the device housing 122 is shown. The carcass stabilizer 166 is connected with the housing side wall 168 that is opposite that which is connected with the rotation device 110. Fig. 11 shows the stabilizer 166 disconnected from the housing 122. The carcass stabilizer 166 includes a shaft 170 inserted through two cylindrical barrels 172 which are connected with the side wall 168. A set screw 174 secures the shaft in place and a lower end hook 176 stabilizes the carcass.

[0041] Figs. 22 and 23 show the carcass stabilizer 366 in use. When a carcass is arranged on the carcass holding device 106 and secured via the spreading plates 126, the inner shaft 170 is extended outwardly, lengthening the stabilizer 166, and the set screw is engaged, retaining the stabilizer in its extended state. The hook 176 is connected with an end portion of the carcass, stretching and stabilizing the carcass for more efficient butchering.

[0042] Once the carcass is arranged on the device, the primal cuts are removed, which is completed in 40-50 minutes due to the ease of butchering with the device. The primal cuts are then packaged and cooled for approximately 60 minutes until an internal temperature of each primal cut reaches approximately 32 to 34 degrees Fahrenheit. From there, the packaged cuts are prepared for shipping. This entire process from eviscerating the cattle to removing, packaging and cooling the primal cuts is completed in approximately 24 hours, well below the industry standard of 3 to 4 days.

[0043] As noted above, removing primal cuts when the carcass reaches a temperature of 75-85 degrees Fahrenheit, as opposed to the industry standard of 44 degrees, significantly reduces the time from kill floor to butchering and packaging. This in turn reduces the potential for pathogens or otherwise harmful bacteria to grow. Butchering beef at a higher temperature is also better for butchers. Removing primal cuts is a difficult task that places a lot of stress on butchers. By butchering at a higher temperature than is standard in the industry, less effort is required for each cut and thus conditions associated with butchering cattle, such as carpel tunnel syndrome, are reduced. [0044] Producing beef with this method is also beneficial to the quality of the meat. As noted above, there is less of a chance of contamination, but also the beef will be of a better quality over beef produced through other methods that often require at least 24 hours of cooling prior to butchering and have a total production time of 3 to 4 days. Because of the decreased cooling time of this method, the resulting meat will be more tender, it will better retain its natural juices and enzymes, and have a shelf life that is approximately two days longer than other methods. Also, as noted above, the rate of shrinkage will be decreased significantly.

[0045] A further benefit of the present method is the reduction of energy needed to produce beef, which in turn will reduce costs and lessen the environmental impact of processing plants that use this method. The reduction of energy results from the shorter time required to cool a carcass prior to removing primal cuts and the overall reduction in time from kill floor to packaging. Moreover, by removing primal cuts prior to lowering beef temperatures to 32-34 degrees Fahrenheit, the size of a cooler for the final stage of cooling prior to packaging can be reduced. For known methods wherein full cattle carcasses are hung in coolers for at least 24 hours until they reach 44 degrees Fahrenheit, a greater number of large coolers, often having a height of approximately 14 feet, are needed to house the many cooling carcasses. For the present method, due to the shorter initial cooling period, a lesser number of large coolers are needed, and for coolers used to reduce the temperature of primal cuts, the size of the cooler can be reduced to approximately 9 feet. Reducing the total number of large coolers and reducing the size of coolers for primal cuts reduces energy usage which in turn provides cost savings and lessens the environmental impact of processing plants.

[0046] Although the above description references particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised and employed without departing from the spirit and scope of the present disclosure.