17 Jan AIR CHILLING OF PROCESSED POULTRY TO ENSURE HIGH MEAT QUALITY AND A LONG SHELF-LIFE

Baader chilling solutions: fast cooling to a predefined deep core temperature

The chilling process determines product appearance, yield performance and shelf life. The ability of chilling to the correct core temperature without freezing extremities will eventually determine the final product value. After meticulously processing each bird to ensure maximum quality and value, it is crucial to effectively minimize bacterial growth and extend product shelf-life. Achieving these objectives is essential for poultry processors to deliver high-quality and safe food.

Air chilling offers in-line processing and does not change the meat structure.Inline air chilling enhances product tenderness and minimizes contamination risks, with controlled weight management through moisturising.

DFS and Baader offer two air chilling solutions: a multi-tier air chilling tunnel and the single-tier clean air tunnel.

More on multi-tier Air Chilling:

Cold air is an effective way to cool down the carcass temperature while the product stays on the overhead conveyor. In the Multi-tier Air Chilling system, cold air is circulated to cool the meat, resulting in a strong flavour and less chance of contamination compared to immersion chilling.

Benefits of Air Chilling

• Fast chilling to desired core temperature
• Moisturising technology to ensure product quality and keep the weight loss to a minimum‍
• Easy temperature management
• Automatic, in-line chilling and maturation
• Multiple tiers ensure small footprint air-chilling‍
• ‍Alternating tier position to reduce cross-contamination caused by dripping
• Preserves meat flavour and texture

Keeping the Chilling Process In-line: Automatic Transfer

Automatic transfer to an in-line air chilling line will reduce product handling and bacterial growth. Using line speed, tunnel length and air flow, the solution will bring products to a predefined deep core temperature. By designing the air chilling solution with several tiers, the overall footprint is reduced to a minimum. The position of the birds in the different tiers alternates to reduce the risk of dripping.

Controlling Humidity and Maintaining Yield

When circulating cold air around the carcasses, the meat temperature is quickly reduced. To avoid drying the surface, a water spray system can be used. When a bird is detected on the line, the system releases a sprinkle of water around the product. The additional humidity will keep the weight loss down.

Maintaining the High Quality

Air-chilled chickens are cooled individually, which reduces the amount of bacteria spreading among products during chilling. Furthermore, as the product is not subject to added water, air chilling is known to preserve the true flavour and meat texture. During cooking, there is no excess water to steam out and the weight loss is minimal.