MEAT+POULTRY - March 2015 - 91

and food safety. And like those detected by
humans, bones detected by machines go up the
line as soon as possible to provide feedback to
operations workers.

MCNUGGETS REVOLUTION
Like the evolving poultry-processing industry,
the chicken-deboning process has had to change
once it became a common practice in the early
1980s. Brad Williams was on the front lines of
this developing industry segment. After earning
his bachelor's degree at the Univ. of Georgia,
his career started in the QA department at
Gold Kist in 1983. Williams went to work with
Cagle's in 1984, focusing on deboning product
for McDonald's, before joining Wayne Farms in
2002, where he is now area complex manager.
Deboning became more prevalent in
response to the rapidly growing demand in
the fast-food segment for boneless breast
meat in the early 1980s. Demand peaked when
McDonald's led the (Quick-Service Restaurant)
QSR segment by putting chicken McNuggets on
their menus and this set the tone for the other
chains. Ever since then, the industry has been in
search of a better mousetrap when it comes to
finding a better way of deboning.
Perhaps the first, most significant change
made to keep up with demand was the shift
away from deboning birds that were hanging
upside down on shackles. Mounting the whole
birds on cones "with its drumsticks pointing
down," says Williams, was a tipping point and a
practice that is universally used today at largescale deboning operations. Once mounted on the
cone, knife-wielding line workers disassemble
the bird, starting with the breast and legs and
pulling the meat off the carcass. Most deboning
lines are designated as either front-half or whole
bird. And while efforts to automate have made
incremental improvements, the task remains
largely dependent on the cutting skill and
technique of the line workers.
As an alternative to deboning shackled
carcasses, some processors opted to trim
poultry carcasses on the table, as workers rolled
them around, making cuts. Once cones became
utilized, production speed was controlled by
speeding up or slowing down the cone line
as many plants had workers disassemble
and debone the entire carcass. At that time,
"line speed was controlled by individual line

"We knew
we couldn't
eliminate bones
but we could
reduce them."

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MEAT+POULTRY - March 2015

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https://digital.meatpoultry.com/sosland/mp/meatpoultry-september-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-august-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-july-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-june-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-may-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-april-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-march-2024
https://digital.meatpoultry.com/sosland/mp/special-supplement-bacon-trends-technology-march-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-february-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-january-2024
https://digital.meatpoultry.com/sosland/mp/meatpoultry-december-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-november-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-october-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-september-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-august-2023
https://digital.meatpoultry.com/sosland/mp/special-supplement-ground-meat-trends-technology-july-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-july-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-june-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-may-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-april-2023
https://digital.meatpoultry.com/sosland/mp/special-supplement-bacon-trends-technology-march-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-march-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-february-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-january-2023
https://digital.meatpoultry.com/sosland/mp/meatpoultry-december-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-november-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-october-2022
https://digital.meatpoultry.com/sosland/mp/special-supplement-ground-beef-trends-technology-september-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-september-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-august-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-july-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-june-2022
https://digital.meatpoultry.com/sosland/mp/special-supplement-meat-alternative-trends-and-technology-may-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-may-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-april-2022
https://digital.meatpoultry.com/sosland/mp/special-supplement-bacon-trends-technology-march-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-march-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-february-2022
https://digital.meatpoultry.com/sosland/mp/meatpoultry-january-2022
https://digital.meatpoultry.com/sosland/mp/-meatpoultry-december-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-november-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-october-2021
https://digital.meatpoultry.com/sosland/mp/special-supplement-ground-meat-trends-technology-october-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-september-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-august-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-july-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-june-2021
https://digital.meatpoultry.com/sosland/mp/meatpoultry-may-2021
https://digital.meatpoultry.com/sosland/mp/special-supplement-meat-alternatives-may-2021
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https://digital.meatpoultry.com/sosland/mp/meatpoultry-march-2021
https://digital.meatpoultry.com/sosland/mp/2021_02_01
https://digital.meatpoultry.com/sosland/mp/2021_01_01
https://digital.meatpoultry.com/sosland/mp/2020_12_01
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https://www.nxtbook.com/sosland/mp/2015_07_01
https://www.nxtbook.com/sosland/mp/2015_06_01
https://www.nxtbook.com/sosland/mp/2015_05_01
https://www.nxtbook.com/sosland/mp/2015_04_01
https://www.nxtbook.com/sosland/mp/2015_03_01
https://www.nxtbook.com/sosland/mp/2015_02_01
https://www.nxtbook.com/sosland/mp/2015_01_01_mp
https://www.nxtbook.com/sosland/mp/2014_12_01
https://www.nxtbook.com/sosland/mp/2014_11_01
https://www.nxtbook.com/sosland/mp/2014_10_01
https://www.nxtbook.com/sosland/mp/2014_09_01
https://www.nxtbook.com/sosland/mp/2014_08_01
https://www.nxtbook.com/sosland/mp/2014_07_01
https://www.nxtbook.com/sosland/mp/2014_06_01
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https://www.nxtbook.com/sosland/mp/2014_04_01
https://www.nxtbook.com/sosland/mp/2014_03_01
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https://www.nxtbook.com/sosland/mp/2014_01_01
https://www.nxtbook.com/sosland/mp/2013_12_01
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https://www.nxtbook.com/sosland/mp/2013_08_01
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https://www.nxtbook.com/sosland/mp/2013_06_01
https://www.nxtbook.com/sosland/mp/2013_05_01
https://www.nxtbook.com/sosland/mp/2013_04_01
https://www.nxtbook.com/sosland/mp/2013_03_01
https://www.nxtbook.com/sosland/mp/2013_02_01
https://www.nxtbook.com/sosland/mp/2013_01_01
https://www.nxtbook.com/sosland/mp/2012_12_01
https://www.nxtbook.com/sosland/mp/2012_11_01
https://www.nxtbook.com/sosland/mp/2012_10_01
https://www.nxtbook.com/sosland/mp/2012_09_01
https://www.nxtbook.com/sosland/mp/2012_08_01
https://www.nxtbook.com/sosland/mp/2012_07_01
https://www.nxtbook.com/sosland/mp/2012_06_01
https://www.nxtbook.com/sosland/mp/2012_05_01
https://www.nxtbook.com/sosland/mp/2012_04_01
https://www.nxtbook.com/sosland/mp/2012_03_01
https://www.nxtbook.com/sosland/mp/2012_02_01
https://www.nxtbook.com/sosland/mp/2012_01_01
https://www.nxtbook.com/sosland/mp/2011_12_01
https://www.nxtbook.com/sosland/mp/2011_11_01
https://www.nxtbook.com/sosland/mp/2011_10_01
https://www.nxtbook.com/sosland/mp/2011_09_01
https://www.nxtbook.com/sosland/mp/2011_08_01
https://www.nxtbook.com/sosland/mp/2011_07_01
https://www.nxtbook.com/sosland/mp/2011_06_01
https://www.nxtbook.com/sosland/mp/2011_05_01
https://www.nxtbook.com/sosland/mp/2011_04_01
https://www.nxtbook.com/sosland/mp/2011_03_01
https://www.nxtbook.com/sosland/mp/2011_02_01
https://www.nxtbook.com/sosland/mp/2011_01_01
https://www.nxtbook.com/sosland/mp/2010_12_01
https://www.nxtbook.com/sosland/mp/2010_11_01
https://www.nxtbook.com/sosland/mp/2010_10_01
https://www.nxtbook.com/sosland/mp/2010_09_01
http://digital.meatpoultry.com/sosland/mp/2010_08_01
http://digital.meatpoultry.com/sosland/mp/2010_07_01
http://digital.meatpoultry.com/sosland/mp/2010_06_01
http://digital.meatpoultry.com/sosland/mp/2010_05_01
http://digital.meatpoultry.com/sosland/mp/2010_04_01
http://digital.meatpoultry.com/sosland/mp/2010_03_01
http://digital.meatpoultry.com/sosland/mp/2010_02_01
http://digital.meatpoultry.com/sosland/mp/2010_01_01
http://digital.meatpoultry.com/sosland/mp/2009_12_01
http://digital.meatpoultry.com/sosland/mp/2009_11_01
http://digital.meatpoultry.com/sosland/mp/2009_10_01
http://digital.meatpoultry.com/sosland/mp/2009_09_01
http://digital.meatpoultry.com/sosland/mp/2009_08_01
http://digital.meatpoultry.com/sosland/mp/2009_07_01
http://digital.meatpoultry.com/sosland/mp/2009_06_01
http://digital.meatpoultry.com/sosland/mp/2009_05_01
http://digital.meatpoultry.com/sosland/mp/2009_04_01
http://digital.meatpoultry.com/sosland/mp/2009_03_01
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http://digital.meatpoultry.com/sosland/mp/2006_12_01
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http://digital.meatpoultry.com/sosland/mp/2006_05_01
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