processing insights

[Sunny Side Up]

Quote:
Maybe it's time to begin to PAY someone with skills and give your friend a well-deserved break!

We struggled with moving live birds from the pasture pen to the cones this time, a process that required 2 people....need to improve moving the birds from the pasture pen to the cones. Im Unwilling to spend SIXTY dam dollars on a plastic confinement cage to move birds!...

You don't need those fancy plastic confinement cages, but perhaps with the numbers of birds you're processing & selling it would be a worthwhile investment. Otherwise, build some of your own with scrap lumber or PVC and wire, or start collecting old rabbit & parrot cages.​

 

[schmism]

Quote:
Maybe it's time to begin to PAY someone with skills and give your friend a well-deserved break!

She gets all the necks, hearts, livers etc for her all natural cat food biz. That and she gets loaded up with fresh veggies from the garden etc. She gets "paid" just not in "cash".

We struggled with moving live birds from the pasture pen to the cones this time, a process that required 2 people....need to improve moving the birds from the pasture pen to the cones. Im Unwilling to spend SIXTY dam dollars on a plastic confinement cage to move birds!...

You don't need those fancy plastic confinement cages, but perhaps with the numbers of birds you're processing & selling it would be a worthwhile investment. Otherwise, build some of your own with scrap lumber or PVC and wire, or start collecting old rabbit & parrot cages.​

ya we talked about what we could use that would be "like" a containment cage. we have a couple of those plastic tubs with the folding tops that hinge on the side.... we figured we could press those into use if we need to next time.

The info your missing on that whole deal is, that part of the issue was due to the large breed roos we used. They are VERY active and would fervently run from you when you tryed to catch them in the pen. The cornish x would sit at the edge. you could just reach in and grab one without any of the others caring.

oh and our "volume of birds" is ONLY 57 birds this year....​

 

[Brunty_Farms]

I have yet to spend the money on those cages too, I have three of them that I really don't even use often. I made my own that will fit 15 broilers on a hot day and 20 on a cool day. I believe I have 14 of them. They are heavy as heck but they get the job done. I paid I think $120 to build all of them, which worked out to be the price of my two plastic cages that hold only 10 birds. Problem with them... I'm constantly repairing them, but it's totally worth it. I need to save up for the investment, as plastic cages are a couple thousand dollars for the amount that I would need. The second biggest problem is handling them. Without two people it's almost impossible to move them. If I'm loading by myself, this time of year I usually am, I keep the cages in the truck. I back up to the tractors load them up and then leave them in the truck overnight and then back right up to the processing shed.

As far as paying someone, that takes time. This year was my first year (8th year doing broilers for sale) that I was able to pay someone all summer to help on a weekly basis. We processed twice a week all summer long and it wasn't easy. Before then, it was all family and friends that I would pay in chickens or trade labor. Until you get to that economy of scale, it's best to just suck it up and work with what you have which it sounds like what you're doing. She will get it, however with roosters it's a bit different than the CX's so keep that in mind. I know that it always slows me up when we do a batch of roosters.

I also run the scalder too, people that are working with you want to do it, but they don't realize that the scald is the most crucial part. If that gets screwed up, you're spending hours fixing the mistake when doing your QC. I did let my help do it a few times this year that way he can do it, and learn. He was slower, but you have to let them learn eventually because you will get tired of doing the same thing over and over and over again. It's nice to sometimes get out of the processing shed and kill..... get some fresh air. I think in the long run when you decide if you want to start hiring employees that it's important to cross train them on just about everything you do.

For catching.... what I used to do prior to cages. I would actually bring up a tractor and work right out of the tractor. I would use it like a big giant cage. I would take the tops of the pens, at this point they are not going to fly so you would just go in and catch one without chasing them all over. Do this the night before and you will be surprised at how much time it saves you. Also, bed it down really well with straw, the birds will be spotless on the really dry straw and makes processing a breeze. No manure in the intestines and clean feathers makes it a treat compared to a rainy day with muddy birds.

Sounds like you've tweaked your system a bit since the last processing of the CX's... It's good to always find new ways to get things done. I'm still always refining something around here to make my life easier. The biggest pain is being frugal to save money but still make it functional and last until you have the money to buy the right table, the right cages, ect.

Good luck.... sounds like your having fun.

 

[eKo_birdies]

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good job on catching THAT many!!!! seriously... that would be tough. i had problems catching some of my freedom ranger roosters (they free range unconfined).. so i can only imagine the fun you had.

 

[averytds]

We use wire storage cubes and zip-ties for transport/temporary cages. Might something like that work for you? http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10051&productId=202024895&langId=-1&catalogId=10053&ci_sku=202024895&ci_src=14110944&cm_mmc=shopping-_-googlebase-_-D23X-_-202024895&locStoreNum=2220&marketID=421

Easy together, easy to break down and store, cheap (watch for sales). K-Mart frequently runs them about $16/box.

 

[bigredfeather]

I have the same dilema w/ crates. I am not spending that much. I can get them for $34, but I would need 10 or more. The last 3 times we've butchered, I put the topper on my pick-up, and loaded the birds out of the tractors and into the back of the truck up the night before. I then back my truck up right next to the killing cone stand. Luckily my topper has flip-up windows on the sides, so between them and the back window, retrieving the birds isn't too bad. I tried moving the tractor right up to the processing area and pulling them out as needed, but it was a lot of work and it was almost a 2 person job. Never again!

We just processed 150 of them on Saturday. We had 1 person killing(6 cones), 1 scalding/plucking, 1 feet/head removal, 2 gutting, and 1 lung scaping/cavity clean-out. It went very well. We averaged 1 minute 36 seconds per bird. If I would have had 1 more person, they would have started on peeling the gizzards. I love the gizzards, but it sure is a lot of work cleaning them. We have done 492 birds this year, and every batch seems to get more streamlined. I built a Whizbang and it is the best thing since sliced bread. Being able to scald and pluck 3 at a time keeps the people at the table hopping. This Winter I want to build a scalder. I aquired a gas hot water heater free, and intend on turning it into a thermostaticlly controlled scalder. I have seen some pics on here (Jaku's) and it looks like it is the answer. As Jeff said, the scald is the key to an attractive dressed bird. My stand burner/metal trash can scalder is tough to keep at a constant temp. It works, but the hot water heater would be much better.

 

[Sunny Side Up]

I'm sorry, Schmism, it just hit me wrong to hear someone complain about the quality of the work they were getting from a friend who was volunteering their help for free. It's smart to assess your processing procedures and try to make the changes necessary to make the next session more efficient & effective. If this friend is slowing things down then perhaps she should be moved to a different task.

I just process my surplus roosters for my own table, and usually have to work alone.

Each time I process I try to think of ways to make the next session go easier, and things have really improved since I first began. I find it much more enjoyable to work with at least one other person, otherwise it gets rather lonely & boring.

Averytds, those storage cubes look like a good way to confine your birds for butchering. How many do you fit into each cube? I find it best to catch the candidates after dark the night before they're butchered, it saves a ton of effort trying to chase them down to catch on the hoof. I have a nice collection of rabbit & parrot cages I use, most of them obtained for free off discard piles in the neighborhood. They make it easy to reach in and pick out one bird at a time, without them putting up a fuss.

You could also make confinement cages from sections of ventilated wire shelving, the plastic coated or the plain. Wire or zip-tie them together and make a hinged door at the top for access. You might need to weigh them down with blocks once the birds are in, but otherwise they'd be fairly lightweight for moving, & could be taken apart for storage.

 

[averytds]

We don't usually assemble as just one cube. For say show transport, we'll make them 2 long/1 deep/2 dividers, so 3 spaces for LF with tar paper or cardboard in the bottoms. I keep some panels in my car just for impulsive purchases.

If nothing else, they make great doors. No hinges to buy, just zip-tie them. The meatbirds in the "brooder" at the moment, well the brooder is a huge rubbermaid tub with six panels zip-tied together. The middle 2 are secured to the tub and the ends flip up for access. The lamps sit right on top.

If you want a solid bottom, they make solid plastic cubes as well, or go with something light weight. Drill a few holes for the ties and go say 2 wide x 2 or 3 cubes deep x 1 cube high. Zip-tie the tops so you can swing a few open.

We use heavy duty spring locks to secure the doors, but that's because I already had them. I'm sure there are lots of other things that could be used.

The only thing to watch for is the grid size. The K-Mart ones are all approx 1", but say the Target ones, more than half the panels are more like 2-3". I like the smaller grid.

 

[davony's chicks]

Great Job schmism!

Are you just processing for yourself or do you sell processed chicken?

I have not processed any birds yet but have been considering it. I have a neighbor that said he would show me how. I was raising a bunch of RIR and BAs to butcher but I sold them as chicks instead.

Thanks for sharing.

 

[schmism]

davony's chicks :

Great Job schmism!

Are you just processing for yourself or do you sell processed chicken?

both.

We had more orders for cornishx this spring than we had birds.

This second batch will likely be half sold half kept. If I can sell all of them i will.​