Processing poultry carcasses after slaughter is a time-consuming process that takes a lot of time and effort from farmers. The hand-plucking of each broiler takes an average of 15-20 minutes, which at large volumes becomes a real test for the hands and nerves. That's why. pen-removal machine with their own hands for broilers It is an excellent solution for small farms, allowing you to reduce the processing time of one carcass to 30-60 seconds.
Creating such a device at home does not require expensive industrial equipment or deep knowledge in the field of mechanical engineering. It is enough to have basic skills of working with metal, power tools and be able to read simple drawings. In this article, we will analyze the design in detail, select the necessary materials and assemble an effective unit that will last for many years.
Principle of operation and device of the perimeter removable machine
The basis of any pen-removal device is the effect on the carcass of rubber fingers, which are fixed on a rotating disk or drum. These elements are called billing-fingerWhen rotating, create friction that knocks the feather out of the skin of the bird without damaging it. The entire design is based on a rigid frame that holds the rotating mechanism and ensures the safety of the operator during operation.
There are two main types of designs: centrifugal (vertical) and drum (horizontal). For home handling broilers are most efficient and easy to manufacture centrifuge. In them, the carcass is placed in a container, the bottom of which rotates, and the bird itself is pressed against the walls by centrifugal force. This ensures uniform processing on all sides.
The key element here is the speed of rotation. Too low speed will not allow you to qualitatively remove the feather, especially the fly. Excessive speed can lead to skin rupture or even bone fractures in a small bird. The optimal range of revolutions for broilers is considered to be from 800 to 1200 rpm, which must be considered when choosing an engine.
⚠️ Attention: When designing, be sure to provide a protective cover or cover. Rotating billet fingers can injure the hands if you accidentally touch them while the mechanism is working.
The device also includes water supply system. The jets of water wash away the plucked feather and down, preventing them from sticking onto the rubber fingers and making it easier to clean the tank after the cycle is complete. Without water, the plucking efficiency drops by 30-40%.
Required materials and tools
Before the assembly, it is necessary to prepare all components so as not to interrupt the work process. The basis of the design is the tank. For broilers, a container of stainless steel or high-quality food plastic with thick walls is best suited, capable of withstanding dynamic loads. Aluminum tanks are not recommended as they deform quickly.
The most important consumable is the fingers. They can be made independently from technical rubber, but it is better to purchase ready-made factory products. They have a special notch and a selected stiffness, ideal for the skin of a bird. For a standard tank with a diameter of 50 cm, about 80-100 pieces will be required.
- 🔩 The engine (electromotor) with a power of 1.5 kW with a speed of about 1400 rpm.
- 🛢️ Metal tank or barrel with a volume of 60-80 liters (diameter about 50 cm).
- 🛞 Shifts for belt transmission or gearbox for reducing revs.
- 🔌 Start capacitor and button on/off with moisture protection.
A belt transmission is used to transmit rotation from the engine to the disc. This allows not only to reduce the speed, but also to protect the engine from overloads: when the carcass is jammed, the belt will simply begin to slip. You will also need a sheet metal 3-4 mm thick to make a rotating bottom.
⚠️ Warning: The engine must be protected from IP54 and above. Working with electrical equipment in conditions of high humidity and the presence of water requires strict adherence to safety measures.
Of the tools you will need: Bulgarian (USM), welding machine, drill with a crowned drill (for holes under the fingers), wrenches and roulette. If you plan to make a frame from a profile pipe, make sure that you have the ability to cut and weld it evenly.
Step-by-step assembly instructions
The assembly begins with the preparation of the tank. If you use a metal barrel, cut the top, leaving the sides 40-50 cm high. In the lower part of the tank, retreating 5-7 cm from the bottom, it is necessary to mark and drill holes for installing billing fingers. The holes are arranged in a chessboard order for better efficiency.
Then we make a rotating disk. It should be less than the internal diameter of the tank by 3-4 cm, so as not to rub against the wall. The disc is cut from metal with a thickness of 4 mm. It also drills holes under the fingers, but here they are located in a spiral from the center to the edges. This creates turbulence and makes the carcass move.
☑️ Pre-assembly check
Installation of the engine is carried out under the tank on a separate frame. The engine shaft is connected to the disk shaft. Direct connection is possible only when using low-speed engines, in most cases, the installation of a gearbox or pulley system is required. The belt should be stretched, but not pulled.
The final stage is the installation of a drain and water supply system. At the bottom of the tank, a pipe is welded to drain dirty water. On the side, at the level of the shoulders of the carcass, you can install a pipe with a crane to connect the hose. All electrical connections must be carefully insulated and raised above the floor.
| Parameter | Importance for broilers | Note |
|---|---|---|
| Diameter of the tank | 45-55 cm | Optimal for 1-2 carcasses |
| Tank height | 40-50 cm | So the bird doesn't jump out. |
| Engine power | 1.5 - 2.2 kW | Depends on the weight of the bird. |
| Disk rotations | 800 - 1200 rpm | Regulated by pulleys |
| Number of fingers | 90-120 pcs. | Including the disc and walls |
Manufacture and installation of billing fingers
The fingers are the “working organ” of the machine. They can be bought ready-made (they are marked by rigidity: for quail, chickens, turkeys) or make yourself. For broilers of medium size, medium-sized fingers are best suited. Homemade fingers are made of thick technical rubber, inserting a metal rod or bolt for fastening inside.
Installation of fingers in the holes of the tank and disk is made tightly, with effort. They should be held by rubbing rubber against metal, but if necessary, they should be able to pull out for replacement. The holes are drilled strictly perpendicular to the surface, otherwise the fingers will work inefficiently and wear out quickly.
The secret of durability of fingers
To rubber fingers last longer, lubricate them periodically with vegetable oil or glycerin. This will prevent rubber from drying out from contact with hot water and will keep the material elastic for many seasons.
The location of the fingers on the disk is critical. If you place them too rarely, the pen will remain. If too often, the carcass will get stuck. The ideal circuit is a spiral that swirls from the center to the periphery. This creates a funnel effect, causing the bird to spin and roll over.
⚠️ Note: When mounting your fingers, make sure that the sharp edges of bolts or studs inside the disc do not stick out and cannot damage the bird's skin or injure the operator when cleaning.
Electrical drive and safety setting
The electrical part is the heart of your pen-removal machine. For a single-phase network 220V, an asynchronous motor with a starting capacitor will be required. The connection scheme depends on the brand of the engine, so find the passport plate on the body. Be sure to use an automatic switch and an RCD (protective shutdown device) to protect against electric shock.
To adjust the speed of rotation, you can use a frequency converter, but this increases the cost of the design. A simpler and more reliable method is the selection of the diameter of the pulleys. If the engine produces 1400 rpm, and 800 are needed, then the pulley on the engine should be less than on the disk shaft, in a ratio of about 1: 1.7.
- ⚡ Use waterproof sockets and switches (IP65).
- ⚡ All wire connections are performed in sealed boxes.
- ⚡ Make sure to make a high-quality grounding of the metal body.
Vibration is the main enemy of this design. The engine and tank must be rigidly fixed on the common frame. Under the legs of the frame, it is desirable to install rubber shock absorbers or wooden bars so that the machine does not "run away" on the floor during operation and does not create unnecessary noise.
Technology of plucking and subtlety of the process
The process of plucking begins with the correct preparation of the carcass. The broiler must be scalded before loading into the car. The water temperature depends on the age of the bird: 55–58 ° C is enough for young broilers, 60–62 ° C is enough for older and larger ones. The scalding time is 40-60 seconds. Insufficiently scalded bird will pluck poorly, and overexposed in boiling water can lose the marketable appearance of the skin.
Load the carcass into a working machine. Turn on the water supply. The process takes 30 to 60 seconds. Keeping the bird in the drum for longer makes no sense - the quality of the pinch will not improve, and the risk of skin damage will increase. After turning off the engine, let the water drain, then remove the carcass.
After each batch (3-5 carcasses), it is recommended to stop the car, turn on the water at full capacity and let the drum work for 10-15 seconds idle. This will wash the fluff and feather into the drain, preventing clogging and sticking dirt onto the rubber elements.
Frequent errors and their elimination
When you first start, there are often problems that are easy to fix. For example, if a bird beats hard against the walls and bruises or tears appear, then the rotation speed is too high or there are few fingers in the tank. Add a number of rubber elements or reduce the pulley diameter on the engine.
If the feather remains, especially on the wings and tail, check the temperature of the oshparki. Often the problem lies in the insufficient softening of the pen pocket. Also make sure that the fingers are not “licked” and have a pronounced working surface.
The main secret of success is the balance between the temperature of the oshpark and the speed of rotation of the drum. The ideal parameters are selected experimentally for each batch of birds.
In case of strong vibration, check the disc balance. It may be welded out of the center or one of the frame supports is shorter than the others. The imbalance will quickly disable the engine bearings, so eliminate the distortions immediately.
Maintenance and maintenance of equipment
The car requires minimal but regular maintenance. After finishing work, wash the tank from the inside with a jet of water under pressure. Periodically, once a season, check the condition of rubber fingers: if they become too soft or cracked, they need to be replaced. Rubber loses its properties over time.
The bearing units of the engine and the disk shaft should be lubricated according to the manufacturer's instructions. If the machine is operated intensively, lubrication is carried out every 10-15 hours of operation. Watch the tension of the belt: sagging belt will slip, and the overstretched will create an extra load on the shafts.
Store the unit better in a dry room, protecting from direct sunlight, which destroy rubber. If the car is wintering in an unheated garage, cover it with a cloth or film so that dust and rodents do not damage the wiring.
What lubricant should I use for bearings?
For bearings in high humidity and contact with organic matter, lithium lubricants with moisture-resistant additives, such as Litol-24 or specialized food lubricants, are best suited if there is a risk of direct contact with the product.
Can you pick up a bird other than a broiler?
Yes, the machine is universal. For quails or small chickens, the rotation speed can be reduced. Turkeys and geese will require stiffer fingers and possibly a more powerful engine, but the principle of operation remains the same.
Why is the skin on the carcass ripping?
The main reasons: too high temperature of oshparki (the skin becomes flabby), excessive speed of rotation of the drum or worn, too stiff billet fingers. Try to reduce the water temperature by 2-3 degrees.
How long does a homemade car last?
In the manufacture of stainless steel and high-quality engine service life is 10 years or more. Plastic tanks may require replacement after 3-5 years of active use due to aging of the material.
Do I need to change the water for each carcass?
No, the water in the tank changes rarely, mostly it is supplied flowing or added as needed to flush the pen. Complete replacement of water in the tank (if it is used as a storage device) is made after the completion of the entire batch.