In recent years, poultry processors have increasingly turned to air-chilled technology as a preferred method for cooling poultry post-slaughter.

Air-chilled chicken has gained popularity due to the growing need for more efficient and environmentally friendly chilling methods. Traditional methods, such as water chilling, often involve refrigerated tank chilling, which uses a significant amount of water. Air chilling reduces water consumption, addressing environmental concerns in many regions.

Historically, the US poultry industry relied on water chilling due to its positive impact on yield, while air-chilling posed yield challenges, making processors hesitant to adopt the technology. That’s no longer the case.

Randy Wilson, industry sales manager for poultry for Marel, the Iceland-based company, with US offices in Lenexa, Kan., explained that unlike traditional water chilling methods, which often involve immersing chickens in large vats of cold water, air chilling uses a controlled air circulation system to cool the birds, offering several benefits for food safety, quality and efficiency.

So, the demand for air-chilled products continues to rise globally, driven by its distinct taste and texture. Unlike water-chilled chicken, air-chilled chicken locks in flavor and retains moisture, making it a more appealing option for consumers.

“Processors who use our air-chilled technology benefit from producing a higher quality meat product, with flavor and moisture locked into the meat,” said Duke Vaughn, sales manager and air chill product specialist for Baader, based in Kansas City, Kan. “This is especially popular in regions where consumers and fast-food chains prefer air-chilled products, as it offers superior flavor and texture compared to other chilling methods.”

Another plus is it leads to more accurate product labeling, as the birds retain their true weight without the added water that often accompanies traditional methods. This not only fosters transparency for consumers but also aids processors in managing pricing more effectively.

What’s Available

The growing demand for air-chilled poultry has led to numerous innovations by manufacturers, with more intelligent drive systems and advanced refrigeration control systems, allowing for improved efficiency.

For instance, the Baader Clean Air Chill System features a one-level air chilling process prior to the birds entering a multi-level maturation room.

“This system is designed with a plenum and ductwork, where the ductwork is strategically positioned above all the passes of track with trolleys and shackles,” Vaughn said. “The clean, dry, cold air is forced through the ductwork, maximizing airflow that enters both the cavity and around the exterior of the chicken. This chilling process ensures the highest quality of air-chilled chicken, preserving its taste and texture.”

After all, the single-level chilling principle eliminates the risk of cross-contamination from overhead birds so the chickens remain in the one-level clean air chill system until their core temperature drops by about 75%, at which point they are relatively dry and can safely move to the multi-level maturation chilling stage.

Air-chilled poultry lines can occupy one level or come in multi-tiered system.

| Source: Marel

Marel has 25 air-chilled lines installed at plants around North America and 350 in 60 other countries around the world. The company offers three types of air-chilled systems and each one of them is unique in its design based on the weight of the birds, Wilson said.

“There’s the old-school Downflow Plus, which is multi-tiered overhead conveyor operators, and you’re trying to get the bird below 40°F without freezing the extremities.”

Another Marel product is the InfraChill, which reduces chill times by some 25% and is the fastest way to get a bird below 40°F.

“The third type is what we call Shock Masteration Chill, a two-stage, multi-tier system where we get the birds really cold in the first part, and then we go into a second tunnel and allow the bird to equalize throughout the body of the bird,” Wilson said. “In the second, longer stage, birds are chilled slowly, using less cold air at lower velocities to speed up proteolytic breakdown.”

Wilson warns there can be horror stories.

“You can freeze wings and legs, and you still won’t have the breast meat core deep down below the required 40°F,” he said. “You also need to maintain the proper level of water film on the bird or else you can have a bird with part of the epidermis on it and part of it off, and you only get one chance to design an air-chilled tunnel to perfection.”

The Road Ahead

As the poultry industry continues to seek better ways to deliver the highest quality products to consumers, air-chilled systems will likely become even more important.

“The ongoing advancements in air chilling technology will ensure that it remains a key consideration for processors looking to improve both efficiency and product quality in the future,” Vaughn said.