Chicken Processing Plant

Plant Layout & Zoning The plant must follow a linear or U-shaped flow to ensure that raw birds and finished products never cross paths. Zone 1: Receiving & Killing (Dirty Zone): Includes the unloading dock, hanging area (shackling), stunning (electric bath), and bleeding. Zone 2: Defeathering (Semi-Clean): Includes scalding tanks (at 50°C–60°C) and mechanical pluckers. Zone 3: Evisceration (Clean Zone): Removal of internal organs, inspection by quality control, and final carcass washing. Zone 4: Chilling & Packing: Quick chilling (air or water) to bring carcass temperature below 4°C, followed by grading, portioning, and vacuum/bag packaging.