Development and implementation of a method optimizing the transport of turkeys from breeders to the poultry processing plant

The movement of slaughter animals is among the most difficult tasks carried out in the agrobusiness sector. In the general opinion of specialists, it should be carried out in accordance with the principles of high welfare. The unfavourable impact of pre-slaughter turnover is particularly observed in poultry, which is characterized by high sensitivity to adverse stimuli that animals encounter during movement. 

• Poultry are exposed to many stress factors: lack of food and water, restriction of natural behavior, destruction of flock hierarchy, reduction of living space, movement, vibration, shock, noise.

The effect is an increase in mortality, weight loss and carcass damage, and deterioration of meat quality. Among the factors affecting the number of falls and carcass damage are the method of catching birds, the time of day of catching birds and the time of day of transportation, the season of the year, in addition, the time of transportation and the time of waiting for unloading and placing on the slaughter line, loading density, as well as body weight, age and sex. Body weight losses during movement are assumed to be 0.2 - 0.5%/hour.

During pre-slaughter turnover, poultry are exposed to various types of carcass damage, which can cause disqualification of the carcass or parts of it. Wing fractures, hip dislocations and leg fractures, with accompanying contusions, are quite common in slaughter poultry. Damage to carcasses can be up to 25%, according to various authors. The cause can be careless handling of poultry during loading, unloading but also grogginess of restless birds. With manual grasping of poultry, 4 - 6% of birds with injuries are recorded, while with mechanical grasping 1- 3%. There is a reduction in the number of birds with hip dislocation from 16.5% to 7%, and in the number of falls during transport from 0.3 - 0.6% to 0.2%.

The adverse effects of ante-mortem stress are the upsetting of the rate of post-mortem changes in meat and the appearance of meat defects. 
It is not possible to completely eliminate the undesirable effects of pre-slaughter turnover and transportation, but it is necessary to reduce these losses.

Solution for the technology and organization of the movement of turkeys to the poultry plant to improve animal welfare - reducing injuries to birds during the process, including loading by about 60%. Mechanization of loading and change of the unloading org. with observance of ergonomic and safety principles.
The operation will improve meat quality for all customers of the plant's products and reduce product losses and food waste. 
Standardized caging of trailers will reduce water consumption in washing and disinfection processes by about 25%. 
Org./mech. of the process will allow optimum utilization of equipment: reduced waiting time for loading and unloading. Reduction of operation times by about 20%.

Project activities

1. Development of constr. guidelines of the device for unloading and placement in the production line zone - model CAD-3D.
2. Development of the control system of the device and 2D design doc. of the prototype. 
3. Purchase of transport assemblies adapted for transporting turkeys.
4. Purchase of assemblies for mechanical loading of turkeys- testing and possible optimization of cage housing.
5. Platform for transporting mechanical loading assemblies  
6. Modernization of turkey hanging line with unloading support equipment with safety systems, reduction of unloading time, construction of prototype mechanical unloading device;
7. Improvement of safety in terms of bioassurance and working conditions for operators in the farm of an operational group member.

Practice summary

The expected result is the development and implementation of a method to optimize the transportation of turkeys from breeders to the poultry plant is primarily to improve the welfare of birds during loading on the farms, shuffling and unloading them at the plant. It is assumed that mechanization of the process through the use of loading equipment will contribute to the elimination of the most serious injuries and a reduction in all bird injuries at this stage by about 60%.

The expected result is also an improvement in ergonomics and occupational safety in the bird unloading area of the Plant. Improved conditions should also contribute to improved bird welfare in the process. During the implementation of the operation, it is also envisaged that the bird cage body will be tested and adapted to standardize and accommodate mechanical loading and unloading. The improved design will make it possible to reduce water chewing in the washing process. An important aspect of the operation will be the development of a prototype device for mechanizing the process of unloading turkeys from the container housing to the production line of the Plant. This should facilitate the work of operators and reduce stress and injury to animals.

Additional comments

Facilitating the implementation of the achieved result may be the confirmed positive effect of execution in the form of reduced losses due to the decrease in damage to turkeys in the processes of pre-slaughter handling - loading, transportation, unloading.

• Improved processes related to the transportation, unloading and placement of birds on the production line will contribute to the optimization of these processes, in addition, it will affect more efficient use of means of transportation, reduce downtime, reduce water consumption in the processes of washing equipment thanks to the optimization of cage housing.
• More efficient washing and disinfection will reduce the risk of transmitting infectious diseases in birds.
• Reducing bird injuries, reducing stress, reducing operational time in the process of loading and unloading and placing turkeys on the production line will improve animal welfare, improve the quality of the Plant's products and reduce production losses and food waste, which is an extremely important issue for the Plant's contractors and consumers. 

The effects of the operation will also increase the production profitability of turkey farms. The positive aspects of the operation's results should facilitate the dissemination of similar solutions.