ATRP RESEARCH NEWS
Last fall, PoultryTech reported on the potential of using an optical biosensor developed by the Georgia Tech Research Institute (GTRI) for the detection of the avian influenza (AI) virus, commonly known as bird flu (PoultryTech, Vol. 20, No. 3, Fall 2008). The optical sensor boasts several advantages over traditional AI identification methods: it is low cost, easy to use, field-deployable, and provides rapid results — less than 30 minutes. Recently, GTRI researchers teamed with colleagues at the U.S. Department of Agriculture’s Southeast Poultry Research Laboratory to validate the sensor’s detection capabilities with experimentally infected live chickens.
Researchers with the Georgia Tech Research Institute’s Agricultural Technology Research Program in conjunction with member companies of the Georgia Poultry Federation have been examining which tasks within a poultry processing plant could relate to lower back pain and injuries. In 1994, the U.S. Department of Health and Human Services, National Institute for Occupational Safety and Health (NIOSH) published the “Applications Manual for the Revised NIOSH Lifting Equation.” However, the NIOSH lifting equation is based on a number of assumptions that do not account for environmental, practical, and procedural factors within a poultry processing plant (see sidebar: “The Applicability of Using the NIOSH Lifting Equation in a Poultry Processing Plant”). This supports the need to determine which tasks have the highest risk for causing lower back pain and injuries, in order to assess proper intervention strategies that reduce the cost of rehabilitation and lost days of work.
By Linda Harley
The revised National Institute for Occupational Safety and Health (NIOSH) lifting equation was released in January 1994. The purpose of the lifting equation was to provide ergonomists a uniform method for evaluating manual lifting tasks in the hope of reducing lower back injuries and stimulate research. The primary assumptions used in the development of the NIOSH lifting equation may not apply to the poultry processing environment.
By Gary McMurray
Gary McMurray, chief of the Georgia Tech Research Institute’s Food Processing Technology Division, discusses current research activities focused on the design and functionality of processing equipment that integrates food safety technologies directly into the equipment.
Excerpted from “Designing food safety into processing equipment,” Poultry Times, August 31, 2009, pp. 4, 10. Reprinted with permission.
At Georgia Tech, we are focused on the development of not only new sensor technology for product screening tasks, but also the design and functionality of processing equipment that integrates food safety technologies directly into the equipment. This is done with the ultimate goal of improving overall product safety and quality and decreasing total cost for food processing plants.
By Al Yancy
In late January of 2008, the U.S. Department of Agriculture, Food Safety and Inspection Service, (USDA, FSIS) published a Federal Register (FR) Notice wherein they formally provided details relating to the Salmonella Initiative Program (SIP). Thirty days later, as the public comment period for this FR Notice was closing, the FSIS announced their intention to issue another such Notice to address aspects of the SIP that had prompted a multitude of questions and reopen the comment period. Almost two years later, the poultry industries are still awaiting publication of the next SIP FR Notice.
Georgia Tech’s Agricultural Technology Research Program (ATRP) is excited about its plans to participate in the 2010 International Poultry Expo (IPE), scheduled for January 27-29 at the Georgia World Congress Center in Atlanta. ATRP’s exhibit will highlight the program’s research advancements and display prototype systems that seek engineering solutions that enhance process efficiency and product safety in today’s poultry industry. Program researchers will be available to answer questions, and a program video and handouts will describe current projects.
The ATRP exhibit will be located in Building B, Booth 3526.
Mark your calendars for June 9 - 11 at the Sawgrass Marriott Resort & Spa in Ponte Vedra Beach, Florida.
Plant and corporate safety personnel will have the opportunity to listen to expert speakers from industry, government, and academia as they deliver up-to-date information on worker/plant safety topics. Attendees will also have the opportunity to participate in round-table discussions, which provide a forum for professionals to discuss problems and ideas relevant to the industry.
The annual conference provides a national forum for information transfer on safety management in the poultry industry, and is co-sponsored by the National Chicken Council, National Turkey Federation, Georgia Poultry Federation, and the Georgia Tech Research Institute’s Agricultural Technology Research Program.
For more information, contact Kristi Spivey at (404) 894-3412 or kristi.spivey@gtri.gatech.edu
An awards ceremony was held October 14 by representatives from the Georgia Poultry Federation and the Georgia Tech Research Institute (GTRI) at Poultry World, the award-winning educational exhibit showcased annually at the Georgia National Fair in Perry, Georgia.
The U.S. Poultry & Egg Association’s Poultry & Egg Institute has released a Poultry Industry Workplace Safety Issues Kit highlighting the progress and the successes achieved by the industry in workplace safety. Since 1994, the poultry industry’s injury and illness incident rate (cases per 10,000 full-time workers) has declined by 73%.
This past June marked the third anniversary of the reissued State of Georgia (GAR000000) general permit for storm water discharges from industrial activities. As expected, during these three years, the U.S. Environmental Protection Agency (EPA) approved Georgia's 2006 305(b)/303(d) List of Waters (impaired stream segments). With two years remaining until the general permit is set to expire, analysis of the data collected by facilities regarding the impact of animal processing activities on impaired streams is expected to begin. For the poultry industry, these milestones are a reminder to review existing storm water pollution prevention plans (SWP3) to ensure that monitoring requirements are up-to-date and that best management practices (BMPs) are working.
The chilling process is one of several key steps used in poultry processing to ensure the safety and quality of products. In this step, eviscerated and defeathered carcasses are dropped into an immersion chiller, which rapidly chills the carcasses to 40 ºF or below and inhibits microbial growth. To further ensure food safety, processors add chlorine or other chemicals to disinfect and sanitize the chiller water.
By John Pierson
Want to get eyes to roll or emotions flowing? Mention conservation, especially water and/or energy conservation. Why? Because many people who have traveled down the conservation path feel it was not worth the trip. Common complaints are that saving water should reduce wastewater and water monthly costs, yet typically savings are minimal or nonexistent due to subsequent rate adjustments needed to offset the utility's reduced revenue. Additionally, when drought conditions occur, the call for reduced water usage often does not exempt facilities already conserving resources. Many also fear that reducing water use will make it more difficult to regain that water resource even if requested for increased production. And now that the recent multiyear drought affects have been worsened through extreme rainfall and flooding, many wonder how conservation, especially as an aspirational goal, can be a beneficial activity that improves the bottom line.
By Paul Bredwell
For months now the development of a federal regulatory program aimed at reducing the emission of greenhouse gasses to the atmosphere has been the topic of much debate. In spite of data that indicates the earth has been in a cooling cycle since 2001, proponents of this program claim this is an essential step in fending off the possibility of long-term global warming. On June 26, 2009, the U.S. House of Representatives passed the American Clean Energy and Security Act of 2009 which, if enacted, will establish a carbon cap and trade regulatory program that presumably will reduce the emission of carbon dioxide and other gasses that various scientists claim are altering the earth's climate. The American Clean Energy and Security Act of 2009 (ACESA) must now be approved by the United States Senate if it is to eventually become a law. Although it appears the bill in its current form faces obstacles within the Senate, it seems likely that some form of climate change legislation will be passed. Assuming this will happen, the question that remains is how will this type of regulatory program affect the poultry industry?
By Abby Vogel
Researchers at the Georgia Tech Research Institute (GTRI) are developing cost-effective techniques for separating and converting poultry processing residuals into higher-value products such as high-grade fuels. The techniques would provide a beneficial use for these byproducts, which are typically blended back into lower-value products.
"Our ultimate goal is to extract usable, quality feedstocks from poultry processing byproducts such as brown grease extracted from wastewater pretreatment processes. If successful, we will help reduce costs by providing a cheap and simple way for the industry to better utilize their low-quality waste oil and grease byproducts," said John Pierson, a GTRI principal research engineer.
By Comas Haynes
An emerging confluence of legislation, funding, and technical progress regarding alternative energy conversion and energy efficiency is resulting in new opportunities for industrial energy systems implementations. This includes cost-effective strategies for implementing combined heat and power (CHP) in mid-sized food processing facilities. Strategically, these opportunities seek to foster "greener" practices within, and perceptions about, the food and beverage industry.
Combined heat and power is the simultaneous generation of "on-site" electricity, heating, and cooling. Historically, CHP has been considered viable only in larger-scale operations (e.g., for regional power and heat loads), but technical advancements and progressive implementations of CHP are making it more feasible for smaller-scale markets such as the food industry.
Combined heat and power (CHP), also known as cogeneration, is the simultaneous production of electricity and heat from a single fuel source, such as natural gas, biomass, biogas, coal, waste heat, or oil. CHP is not a single technology, but an integrated energy system that can be modified depending upon the needs of the energy end user. CHP provides on-site generation of electrical and/or mechanical power; waste-heat recovery for heating, cooling, dehumidification, or process applications; and seamless system integration for a variety of technologies, thermal applications, and fuel types into existing building infrastructure.
Gary McMurray has been named chief of the Georgia Tech Research Institute’s (GTRI) Food Processing Technology Division (FPTD). McMurray assumed the leadership post on April 1 following the retirement of Craig Wyvill. McMurray has been with the division for 19 years, most recently serving as head of the robotics and automation systems research program. He brings a wealth of knowledge in food processing technology system development and is committed to further strengthening the division’s research programs and university and industrial collaborations.
Related story:
Gary McMurray Tapped to Lead GTRI’s Food Processing Technology Division
Researchers at the Georgia Tech Research Institute (GTRI) recently completed preliminary modeling and testing of key cutting control techniques for their Intelligent Deboning System, which they believe will allow automated deboning systems to match if not exceed the yield and quality performance of the best manual deboning processes.
The team is focused on the shoulder cut common to breast deboning. Although automated leg and thigh deboners are in use in many poultry processing plants, automated breast deboning machines are not as prevalent. There are several reasons for this: the natural size variation of birds, the deformable nature of the bird carcass, and variations in the placement of the bird on the cone.
A washdown-ready robot for packing fresh meat into trays, developed by Georgia Tech Research Institute (GTRI) engineers, recently underwent ten months of in-plant testing at Cargill Meat Solutions in Newnan, Georgia. The in-plant tests were conducted as part of a multi-year study funded by Georgia’s Traditional Industries Program for Food Processing and GTRI’s Agricultural Technology Research Program, focused on verifying the robot’s ability to withstand daily caustic and high-pressure cleanup; its operational performance over extended hours; and its accuracy in placing fresh meat products into trays.
Related Story:
Developing a Washable Robot for Poultry Processing
Georgia Tech Research Horizons Magazine
By Abby Vogel
Alerting technicians in a food processing plant about a substandard item on the processing line could be much easier in the future with a laser projection system developed by researchers at the Georgia Tech Research Institute (GTRI).
“We’ve developed a system that shines a laser light symbol onto the imperfect food product so that it can be removed from the conveyor belt, allowing technicians to maintain their focus on the product stream without the need to look up at a monitor,” said GTRI research engineer Simeon Harbert.
By Colin Usher
Vision systems are becoming commonplace in many manufacturing operations for tasks such as quality assessment and process control. These systems bring the added benefits of high-speed, continuous, and uninterrupted operation. Unfortunately, food processing has not realized the same level of success with vision system implementation as other manufacturing sectors. This is because the food processing environment places a unique set of hardware requirements on the system design. While the costs associated with the electronics required to fabricate a new vision inspection system have dropped, the real expense is in the hardening of such a system for a food processing environment. The design and fabrication of the enclosures and conduits must withstand the rigors of the food processing environment and protect the sensitive electronics contained inside from the routine washdown and sanitation practices.
For the past decade, the Georgia Tech Research Institute has been developing vision inspection systems for various food processing applications from chicken breasts to the bread buns they are served on. During this time, these imaging systems have evolved to meet the unique set of requirements placed upon them.
By Gary Floyd, Industrial Segment Manager – Georgia Power Company
The increase in corn prices and energy costs in 2008 has put more pressure on poultry companies to find ways to be more energy efficient and reduce their electric costs. The utility industry, state agencies, and consultants are being called upon to perform energy audits at processing plants throughout the country. An energy audit is an excellent method for establishing energy consumption and identifying opportunities to lower energy usage and costs.
There are many avenues for pursuing energy savings, but they generally fall into three categories: first, low-cost measures to be implemented immediately; second, projects that will take an initial investment but have quick paybacks; and finally, projects that may be more attractive in the future if energy costs increase.
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