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Summary

This video takes viewers inside a poultry processing plant in Teixeira de Freitas, showcasing the step-by-step process of chicken production. From the arrival of live chickens to their final packaging, the tour covers key stages including humane slaughtering, scalding, de-feathering, evisceration, quality checks, and hygiene measures. Emphasizing food safety, the plant follows strict sanitization protocols and uses protective equipment for workers. The video provides an insightful look into the complexities behind the production of chicken, ensuring high-quality standards before the product reaches consumers.

Takeaways

• 😀 The poultry production process starts with receiving the animals at the facility, where they undergo a stress-reducing nebulization and ventilation treatment.
• 😀 After being unloaded, the birds are placed on a conveyor belt and go through an insensibilization process to ensure they are stunned before the slaughter, in line with humane slaughter practices.
• 😀 Approximately 140 to 150 employees are directly involved in the production process of the poultry at this facility.
• 😀 The facility processes various types of poultry, including laying hens, broilers (chickens), and breeding hens that are responsible for egg fertilization.
• 😀 Laying hens are eventually discarded after their egg production decreases, being transformed into raw material for processing.
• 😀 The poultry undergoes scalding in tanks at temperatures between 60-65°C, which facilitates feather removal as part of the preparation process.
• 😀 Some production areas require employees to pass through sanitary barriers, ensuring hygiene and preventing contamination from external agents on clothing and footwear.
• 😀 The facility uses stringent hygiene measures, including boot washing and hand sanitization, to prevent cross-contamination and ensure product safety.
• 😀 At the 'observation' stage, internal cleaning and removal of inedible parts, such as organs, are done, and any poultry showing signs of disease is removed from the production line.
• 😀 Employees are trained to handle various parts of the production line safely, and quality checks are in place to avoid any product re-entering the line or causing a workflow disruption.
• 😀 The plant adheres to strict cold chain management, with poultry being rapidly frozen at temperatures as low as -12°C and stored in specialized cold rooms until shipment.

Q & A

What is the first step in the production process at the slaughterhouse?

The first step is the arrival of the animals by truck, which are then placed in a waiting pen. This helps to reduce stress before they undergo the next steps in the production process.

How does the company ensure humane slaughter practices?

The company uses a stunning process, where the animals are submerged in a stunning tank to render them unconscious before the bleeding process begins. This ensures the animals do not suffer during slaughter.

How many employees are involved in the production process?

Around 140 to 150 employees are directly involved in the slaughter and processing line.

What types of chickens are processed at the facility?

The facility processes broilers (chickens raised for meat), layers (egg-laying chickens), and breeding hens, which are responsible for egg fertilization.

What happens to hens once their egg production declines?

Once hens no longer produce eggs efficiently, they are considered 'cull' birds. These birds are sent to the slaughterhouse, where they are processed into meat products.

What is the scalding process, and why is it important?

Scalding involves immersing the chicken carcass in hot water (60-65°C) to loosen feathers, making it easier to remove them. It is a crucial step for cleaning the carcasses and preparing them for further processing.

How does the facility prevent contamination during the production process?

The facility has several hygiene measures in place, including boot and hand washing stations, along with sanitization procedures. Employees also go through multiple hygiene barriers to prevent cross-contamination.

What are 'good manufacturing practices' and how are they applied?

Good manufacturing practices (GMP) are a set of guidelines that ensure products are consistently produced and controlled according to quality standards. The facility applies these practices by maintaining cleanliness, sanitizing equipment, and ensuring employees follow proper hygiene protocols.

Why is the use of personal protective equipment (PPE) critical in this environment?

PPE is essential to protect employees from hazards such as temperature extremes, physical injuries, and contamination. Employees wear specialized clothing like thermal boots, gloves, and jackets to safely handle products, especially in colder sections of the facility.

What is the process for the final packaging and distribution of the chickens?

After the cooling and processing stages, the chickens are packaged in primary and secondary packaging. The final product is then weighed and ready for shipment, typically in boxes weighing 18kg each, which are prepared for distribution.