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Defects of Pre- and Post-Deboned Broiler Breast

USDA, Agricultural Research Service, Russell Research Center, P. O. Box 5677, Athens, GA 30604; Phone: (706) 546-3132; FAX: (706) 546-3633

Correspondence: D. P. Smith, E-mail:dsmith{at}saa.ars.usda.gov

To assess processing defects and bones in breast meat at one commercial broiler processing and deboning plant (utilizing both manual and semi-automatic deboning methods), 12 months of inspection data were collected and analyzed to determine the incidence and categories of front half defects prior to deboning; the incidence and categories of bones remaining in boneless fillets (Pectoralis major) and tenders (Pectoralis minor); and the effect of deboning method on incidence and categories of bones in fillets. From 248 processing shifts, 34,402 front halves were inspected. A total of 52,561 defects were recorded and were, in order: broken ribs, broken clavicles, broken keels, missing wings, lungs remaining, feathers remaining, and mangled. All of these defects, except missing wings, varied significantly by the month of the year. After deboning, 300,299 lb of fillets were inspected, with 379 total bones found, including, in order: clavicles, fan bones (laterodorsal sternal process), ribs, and scapulas. Also after deboning, 186,310 lb of tenders were inspected with 428 total bones found, including, in order: clavicles, fragments, and fan bones. During 42 shifts, fillets were inspected separately between the manual and semi-automatic deboning methods; no significant difference was detected between incidence and categories of bones found. In this study front halves averaged 1.5 defects each (mostly broken bones); the redominant bone found in boneless meat was the clavicle; and deboning method had no effect on bone incidence for fillets.

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