Each water and chemical compounds are important for meals security in poultry processing and are wanted in massive quantities. Poultry processors rely closely on water, utilizing it throughout processing and for sanitation, with some steps utilizing 80 gallons of water per minute. In keeping with Meals Northwest, your complete course of makes use of roughly 3.5 to 7.0 gallons of water for each four-pound common weight hen processed.
Heavy water utilization isn’t solely dangerous to the setting, but it surely’s additionally pricey for poultry processing services. Services should pay for the water and subsequent wastewater therapy earlier than it’s discharged from their services. The present price at which processors are utilizing water is unfeasible for the long run when contemplating challenges reminiscent of water shortages, tightening authorities rules, and labor struggles. Add the overuse of chemical compounds and vitality to the combo, and processors face an ideal storm of challenges.
How can services mitigate a few of these considerations? From small, constant efforts like audits to extra important investments in automated tools, there are a number of alternatives to save lots of assets in poultry processing with out compromising meals security.
1. Analyze Gear and Processes to Find Potential Financial savings
Step one processors can soak up these efforts is to judge the primary processes and tools that use probably the most water. Scalding, de-feathering, eviscerating, washing, cleansing, and conveying require massive quantities of water, as do inside/exterior washers, chillers, and dip tanks.
At these levels, processors can create important water and chemical financial savings utilizing water reclamation and reconditioning, automation, or different efforts. Processing services can recoup this water and recirculate it to different tools upstream, reminiscent of eviscerating tools or scalders. Recuperation can doubtlessly save a whole lot of gallons of water from taking place the drain.
Moreover, processors can conduct prolonged runs on tools like chillers to keep away from dumping massive quantities of water and chemical compounds as usually, since some services are operating fewer shifts, thereby utilizing extra water for much less product. Efforts like proscribing water nozzles to increased strain and decrease circulation may also add incremental water financial savings over time. Be aware that increased pressures can create splash again, which is a meals security concern in RTE areas.
2. Conduct Routine Upkeep on Small Items of Gear
Water nozzles, spray heads, distribution piping, and even warmth exchangers are areas the place processors could also be dropping water, chemical compounds, and vitality; they’re additionally locations which can be straightforward to miss. Particularly, water nozzles can put on down rapidly and use way more water than they did when initially put in. Checking water nozzles month-to-month and changing them each six months may help processors keep away from dropping as much as a number of gallons of water per minute. Leaks within the plant distribution system must also be recognized and repaired promptly.
3. Automate Sanitation and Intervention Practices
Automating processes and tools can create probably the most important financial savings all through a plant and may offset water utilization in areas the place water is troublesome to recoup, reminiscent of evisceration. Centralized cleansing techniques and low water strain sanitation items might be significantly efficient at decreasing water and chemical utilization by supplying the proper strain, circulation, and chemical focus to belts, rotating tools, and different locations requiring sanitation. Some automated sanitation techniques have been confirmed to cut back water utilization by 50% and save on waste-water therapy prices. Along with water financial savings, automated sanitation techniques may help offset the labor scarcity challenge. In fact, adjustments to sanitation procedures designed to cut back water consumption ought to all the time be verified as efficient.
Whereas automated sanitation tools has been accessible for a while now, new intervention applied sciences are revolutionizing how antimicrobials are utilized to meat and poultry. Conventional antimicrobial utility in poultry processing has been restricted to dip tanks or unfocused sprays, utilizing massive quantities of water and chemical to make sure efficacy. Nevertheless, with improvements in electrostatic know-how (the identical know-how used to use spray paint to vehicles), poultry processors can now notice important financial savings in water and chemistry utilization whereas attaining log elevated reductions to assist compliance with new USDA Meals Security and Inspection Service regulations for Salmonella.
4. Speak to a Meals Security and Sanitation Knowledgeable
The easiest way to create a holistic sustainability plan is to seek the advice of with suppliers. The best tools, chemical, and sanitation supplier can audit a facility and supply suggestions on methods to create efficiencies and decide which processes may very well be automated. Finally, implementing sustainable practices with out compromising meals security takes a dedication to innovation and a collaborative effort between meals security companions.
Sustainability: The Way forward for Poultry Processing
Federal, state, and native rules on water utilization and wastewater are solely going to turn out to be extra stringent, and the water provide turns into extra restricted by the day. Meaning poultry processors—together with the meals processing trade as a complete—might want to consider their processes and tools for tactics to save lots of, and the earlier the higher. The excellent news is that the trade now has extra know-how and methods for overcoming these challenges than ever earlier than.
With the best sustainability efforts and meals security consultants at their disposal, sustainable poultry manufacturing is in attain for processing services.
Ogren is president of Birko’s tools division. Attain him at bogren[email protected].