controlled atmosphere stunning for poultry processing
TRANSCRIPT
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Controlled Atmosphere
Stunning for Poultry
Processing
Dianna V. Bourassa, Ph.D.
North American Meat InstituteAnimal Care & Handling Conference
October 17, 2019
Auburn UniversityDepartment of Poultry Science(334) 844-2610
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Alternative Stunning Methods
• Why are we talking about this?
▫ Consumer pressure?
▫ Activist pressure?
▫ Expert opinions?
▫ Regulations?
▫ Improved welfare?
▫ Improved meat quality?
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Controlled Atmosphere Stunning
Commitments• Perdue Farms
• Pilot Programs/Product Lines
▫ Tyson
▫ Wayne Farms
• McDonalds by 2024
• Global Animal Partnership
▫ 150 Company Commitments
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• &pizza• 241 Pizza• AccorHotels• American
Food & Vending
• Applegate• Aramark• Aroma
Espresso Bar• Au Bon Pain• AVI• B.GOOD• BareBurger• Barilla• Barnes &
Noble Cafe• Benihana• BJ's
Restaurant• Black Bear
Diner• Blaze Pizza• Blue Apron• Blue Sushi
Sake Grill• Boston
Market• Boston Pizza• Brioche Dorée• Bruegger's
Bagels• Burger King• Burgerville• Butcher Box• Butcher's by
RoliRoti• Caesars
Entertainment
• Campbell's• Caribou
Coffee• Carnival Corp• Centerplate• Chipotle• Chopt Salad• Chronic Tacos• Coffee Time• Compass
Group• Conagra• CoreLife
Eatery• Corporate
Dining Services
• Creative Dining Services
• Delaware North
• Denny's• Dunkin
Donuts• EatN' Park
Restaurants• Eggsmart• Einstein Bros.
Bagels• Elior Group• Emmer & Co• Epicurean
Feast
• Fare Resources• Farmer's Fridge• Firebirds Wood
Fired Grill• Firkin Pubs• First Watch• Food For Thought• Fresh & Co.• Fresh Brothers• Fresh Ideas• Fresh Thymes
Eatery• General Mills• Genuine Foods• Guckenheimer
Enterprises, Inc• Guest Services• Healthcare
Services Group• HelloFresh• HHS Culinary &
Nutrition Solutions
• Hip Chick Farms• Honeygrow• Jack in the Box• Jack's Family
Restaurants• Jamba Juice• John J. Jeffries• Just Salad• Kraft-Heinz• La Madeleine
French Bakery &
Cafe• Le Pain Quotidien• Legends• Lessing's Food
Service Management
• Local Kitchen & Wine Bar
• Luna Grill• Manhattan Bagel• McAlister's Deli• McCain Foods• Mellow
Mushroom• Metz Culinary
Group• Mia Fresco• Mimi’s Café• MMI Dining
Systems• Moe's Southwest
Grill• Nathan's Famous• Nestlé USA• New Orleans Pizza• NexDine• Noah's Bagels• Noodles and Co.• Norwegian Cruise
Lines• Nourish Sequim• Opaa! Food
Management• Papa John's Pizza
• Parkhurst Dining
• PCC Community Markets
• PeachDish• Peet's Coffee
& Tea• Pita Pit• Pollo Tropical• Pomptonian
Food Service• Pret A Manger• Qdoba• Quest Food
Service Management
• Quiznos• Red Robin• Revolution
Foods• Robin's• Rootastes• Royal
Caribbean Cruises
• Ruby Tuesday• Scholtsky’s• Second Cup• Serenity Kids• Shake Shack• Smitty's• Snap Kitchen• Sodexo• Sonic Drive-In• Souplantation• Southern
Foodservice
• Spectra• Starbucks• Sterling
Spoon Culinary Management
• Subway Restaurants
• Sun Basket• Sweet
Tomatoes• sweetgreen• Taco Cabana• Tender
Greens• TGI Fridays• The Friendly
Greek• The Plant Cafe• The Star Pizza• Thomas
Cuisine• Tim Hortons• Tribalí Foods• True Taste
Kitchen• UNFI• Unidine• Unilever• Union Square
Hospitality Group
• Walden Local Meat Co.
• WhitsonsCulinary Group
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WATT/Rennier Poultry Confidence
Index Survey – end of 2017• “By the year 2024, what percentage of the U.S.
industry’s total broiler slaughter will be via atmosphere stunning (CAS)?”
How Much CAS Response
None 2%
1-9% 4%
10-24% 30%
25-49% 32%
50-75% 19%
>75% 12%
WATTAgNet.comMarch 1, 2018
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Reported December 2012
https://ec.europa.eu/food/sites/food/files/animals/docs/aw_practice_slaughter_study_stunning_poultry_en.pdf
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Potential Costs
Factors (12,000 bph) Electrical CAS LAPS
Full Cost of Installation $144,000 $1,573,000 $1,500,000 ??
Maintenance (% of installation cost)
3.45% 6.90% 2.40%
Reception/Hanging Labor 97 hours/day 90 hours/day 90 hours/day
Water for Stunning/Cleaning 2,378 gal/day 925 gal/day 925 gal/day
Electricity 5.2 kwh/day 127 kwh/day 1136 kwh/day
Gas Used n/a 6,834 lbs/day n/a
Other Labor 3 hours/day 5 hours/day 5 hours/day
Average cost per bird $0.0288 $0.0413 $0.0312
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Main Drivers for CAS Use
Main Drivers Factors
Working conditions Bird handling
Mechanization Reduced labor cost
Quality/Revenue Improvement over high voltage stunning
Access to capital Larger integrators
Bird throughput Larger numbers = less cost/lb
Animal Welfare/Consumer Demands Markets, labeling, perceptions
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Main Barriers for CAS Use
Main Barriers Out of 17 members
High investment costs 76%
Insufficient capital for investment 41%
Space issues for installation 35%
Planning requirements 18%
No market premium for CAS meat 35%
No/limited cost savings 18%
Lack of experience with CAS 29%
Other (Halal, gas storage, technical failure) 29%
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Controlled Atmosphere Stunning
• Not ”one size fits all”
• A variety of systems to choose from
• Ongoing system design improvements
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Controlled Atmosphere Stunning
• Multi-phasic Systems
▫ Typically 2-5 phases
Induction Transition Completion
Induce unconsciousnessSuppressed ECG and EEG
UnconsciousSlow breathing
UnconsciousNo respiratory responseIrreversible stun
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Controlled Atmosphere Stunning
• Gas Systems
▫ Hypercapnic (carbon dioxide)
▫ Hypercapnic/hyperoxygenic (carbon dioxide and oxygen)
▫ Anoxic (Argon, Nitrogen, etc.)
• Pressure Systems
▫ Low atmosphere pressure stunning (no gas)
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Controlled Atmosphere Stunning
• System types
1. Linear
2. Chamber
3. Underground
• Transport module use
▫ Dump-type
▫ Drawer-type
• Transfer of birds to shackles
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System Types
1. Linear
2. Chamber
3. Underground
Induction Transition Completion
Induction
Transition
Completion
InductionTransition
Completion
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Transport Modules
Dump-type examplePros: Already in useCons: Filling and dumping
Drawer-type examplePros: Ease of filling and no dumpingCons: Capital investment
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Transfer of Birds to Shackles
1. Dump from coop – prior to stun
2. Dump from coop – following stun
3. Shacked from drawer
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Examples of Available Systems
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• Two-stage CO2
• Conveyor• Stun in transport modules• Dump after stun
www.humaneaire.com
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• Multi-stage CO2
• O2 added during induction• Conveyor• Dump before stun
www.marel.com
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• Five-stage CO2
• O2 added during induction• Conveyor• Stun in drawers• Shackled from drawer
www.baader.com
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Conveyor, Stun in Drawers
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• Four-Five-stage CO2
• Chamber• Stun in transport modules• Dump after stun
www.meyn.com
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• Multi-stage CO2
• Underground• Stun in drawers• Shackled from drawer
www.baader.com
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Underground, Stun in Drawers
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Underground, Stun in Drawers
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Underground, Stun in Drawers
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Underground, Stun in Drawers
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Controlled Atmosphere Stunning
With added gasses - CO2 or CO2/O2Advantages Disadvantages
• Unconscious when shackled
• Consistent stun regardless of bird variability
• Potential for improved meat quality (hemorrhaging)
• Potential for minimizing broken wings and leg bruising
• Broilers cannot recover
▫ Will not recover consciousness
• More expensive
▫ Initial cost
▫ Gas costs
• Larger footprint
• Length of time to unconsciousness
▫ Induction phase
• Broilers cannot recover
▫ No ventilation reflex
• Broilers cannot recover
▫ Will not recover consciousness
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Low Atmosphere Pressure Stunning
• LAPS
• Stun in whole module
• Slow decrease of atmospheric pressure until loss of consciousness
www.LAPSinfo.com
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Low Atmosphere Pressure Stunning
www.LAPSinfo.com
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Controlled Atmosphere Stunning
Low Atmosphere Pressure Stunning
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Controlled Atmosphere Stunning
Low Atmosphere Pressure StunningAdvantages Disadvantages
• Unconscious when shackled
• Consistent stun regardless of bird variability
• Potential for improved meat quality
• Potential for minimizing broken wings and leg bruising
• No recurring gas cost
• EU approved
• Broilers cannot recover
▫ Will not recover consciousness
• More expensive
▫ Initial cost
• Not widely adopted
• Larger footprint
• Length of time to unconsciousness
▫ Induction phase
• Broilers cannot recover
▫ No ventilation reflex
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How do these alternative stunning
systems apply to Halal slaughter?
• ESMA defines standards
• Middle East imports ~86% chicken consumption
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How do these alternative stunning
systems apply to Halal slaughter?
• Breathing vs. Heartbeat
• What does it mean to be alive?
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Breathing vs. Heartbeat
• Breathing
▫ Rhythmic motor output
• Heartbeat
▫ Electrical impulses independent of the brain
▫ Will continue to beat until oxygen is depleted
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CAS – Carbon Dioxide for Halal
Example Broiler Stunning Parameters
Parameter Halal Typical
Induction CO2 15% 25%
Transition CO2 55% 74%
Completion CO2 75% 89%
Total stun time 4.5-6 minutes 6-8 minutes
Time to neck cut <45 seconds ~ 100 seconds
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Approximation of CO2 vs. Time
0
10
20
30
40
50
60
70
80
0 1 2 3 4 5 6 7 8
Pe
rce
nta
ge
Ca
rbo
n D
iox
ide
Time (minutes)
Halal Typical
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How do they know the bird is alive?
• No respiratory reflex
• Heartbeat test
▫ 5 birds per load (~7,000 birds)
▫ Conducted between stun and neck cut
▫ Place hand on neck area
▫ Feel for presence of heartbeat (pulse)
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a b64%
c53%
d40%
Low AtmospherePressure Stunning
Martin, et al. 2016. Physiol. & Behavior. 163:25-36
4.5 min
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Topics to Address
• As more CAS systems are installed, more questions arise.
▫ Ambient/bird temperature effects
▫ Relative humidity effects
▫ Time between exit CAS and knife
How long is too long?
▫ Line stops
Any welfare issue?
Quality issues?
▫ Carcass and meat quality
▫ CO2 emissions
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Controlled Atmosphere Stunning
• Much to consider• Should you switch from electrical to CAS?
▫ Dependent on customer base
• If so, what type of system will best suit your needs?▫ Space available▫ Initial costs▫ Long term costs▫ Long term planning and goals
• Many CAS options available to suit a variety of needs.
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Thank you!
Contact:Dianna V. Bourassa, PhDAuburn UniversityDepartment of Poultry Science(334) [email protected]