Field Trip: Poultry Processing

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Estimated time to read:

8–12 minutes

Earthy-green, bright, and warm­ing — this is what chick­en tastes like. My mouth watered as I carved into the roast chick­en, and famil­iar aro­mat­ics filled the air. It’s not any­thing you could get around town or even in a big city. No one would ask for the recipe, and there isn’t one real­ly to write down. What rest­ed on my father’s Sunday table was home cooking.

The whole roast­er was only a few shades dark­er than the white plat­ter it sat on. My father, ever health-con­scious, light­ly coat­ed the skin with olive oil. He used no salt on account of his high blood pres­sure (the table­spoon of soy sauce he rubs on is low-sodi­um and there­fore doesn’t count). He stuffed the cav­i­ty with a fist-sized bun­dle of home-grown lemon­grass with gin­ger and anise. These slim sea­son­ings on store-bought poul­try would be pal­try. Fortunately, this bird did not come from Kroger or Walmart. 

The day before, I slipped the sev­en-pound roast­er into his fridge. I had called ahead, but he was already at the gro­cery store shop­ping for our Sunday Brunch. He list­ed off what was on the menu: brus­sels sprouts, eggs, dis­count bread, fruit for the grand­ba­by, and of course, pan­cake mix. I told him if he want­ed to cook it, I had a whole chick­en for our meal. It was local­ly raised, not pre-brined, and best of all, free! 

“Where did you get it?” he asked, a lit­tle skep­ti­cal. I hoped my reply would impress him.

The experience of processing a chicken

Just before load­ing it into my car, I wrapped a twist tie around the plas­tic bag that had shrunk­en around the whole chick­en. It was the final step in a process that had tak­en up most of my Saturday. Levi Burg, a Clark County Extension Agent, encour­aged us to freeze or cook the raw meat as soon as pos­si­ble while he dipped anoth­er chick­en-filled bag into a steam­ing pot of water. He kept a watch­ful eye on the half-dozen of us who had shown up for his Poultry Processing work­shop. As an exten­sion agent, he ensured we fol­lowed food-safe­ty pro­to­cols. As a life­long farmer and hunter, he guid­ed us through the hands-on work­shop with con­fi­dence-build­ing instruction.

In this last hour, my class­mates and I hunched over indi­vid­ual cut­ting boards to prac­tice our new skills. I spent most of my time at the part­ing-out sta­tion, find­ing a cer­tain sat­is­fac­tion in maneu­ver­ing around bone, cleav­ing off a per­fect piece of thigh, or snap­ping a wing into flats and drum­sticks. The woman next to me did not share my enthu­si­asm. A green­ish gri­mace crossed her face every time I cracked apart the joints. She waved a hand for me to con­tin­ue as she worked to over­come her squea­mish­ness. This was prac­tice, after all. The first chick­ens I part­ed out pro­duced ragged-edged breasts with bite-sized chunks of meat still cling­ing to the ribcage. I removed the pro­trud­ing bone bro­ken from ear­li­er mis­han­dling and stripped off pin­feath­er-stud­ded skin.

The work chilled my fin­gers. Salted ice water dripped onto our cut­ting boards as we sort­ed the birds. This one whole. This one part­ed out. This one spatch­cocked. We inspect­ed our ear­li­er work, though it was impos­si­ble to know who had worked on which bird. They were sub­merged togeth­er in cool­ers filled with salt and ice water. Levi explained this was an essen­tial step — to reduce con­t­a­m­i­na­tion and to pro­duce a more ten­der bird, the chick­ens need­ed to chill for over an hour.

It seemed odd to eat lunch dur­ing that hour. We crunched salty chips, sipped Ale‑8, and tore into cold-cut sand­wich­es. Most folks chose roast beef and avoid­ed the turkey. We rest­ed in the Extension Office’s teach­ing kitchen, grate­ful to be back inside, shel­tered from the new­ly arrived autumn wind. The morn­ing had been cold­er than any of us expect­ed, and most of us wore only a sweater we didn’t mind dirtying.

In fact, the plas­tic aprons Levi pro­vid­ed were in the trash well before our lunch break. The wind kept whip­ping them around our tor­sos, prov­ing to be more of a nui­sance than help­ful. The gloves were a dif­fer­ent story—many kept at least one of the thick gloves on. They were designed to be “cut resis­tant” as we learned to use our tools prop­er­ly, but their main advan­tage was keep­ing our hands warm from the cold air. 

It was with my gloved hand that I grasped the limp, bloat­ed neck of the chick­en. With my oth­er hand, the knife sliced clean­ly through skin and mus­cle, slip­ping between ver­te­brae to sev­er the blood-filled neck from the meaty car­cass. The neck joined the scaly feet in the trash. Before these appendages were removed, what lay before me had still felt like an ani­mal. Its life­less head flopped over the edge of the table. 

I didn’t look into its eyes. Rather than reflect­ing on the cir­cle of life, I focused on the task at hand—my ungloved hand inside the chicken’s body cav­i­ty. The organs were hot and slick. Using my index and mid­dle fin­gers, I scraped out the lungs and pulled free the heart. Earlier, I had removed the crop, stom­ach, liv­er, and intestines as one con­nect­ed mass. My great­est fear was tear­ing the intestines and spilling their con­tents onto the bird and work­sta­tion. Navigating by touch, I pressed the backs of my fin­gers against rigid bone, let­ting soft organs pass under my fin­ger­tips as I turned my wrist to sev­er con­nec­tive tissue. 

Though the work was vis­cer­al, I felt more con­fi­dent using my hands than the knife. A reminder of my ear­li­er mis­step lin­gered a few feet away: a bright green stain on the white plas­tic table where I had nicked the gall­blad­der while sep­a­rat­ing it from the edi­ble liv­er, spilling a thim­ble­ful of bit­ter bile onto our work­space. With that mis­take in mind, I worked care­ful­ly as I cut the cloa­ca free from the abdomen, mind­ful not to let the knife’s point pierce deep­er into the organs within.

Of course, I couldn’t make the punc­ture until the bird was free of feath­ers. Our group plucked the birds by hand—a task requir­ing both fine dex­ter­i­ty and patience. Grasping pin feath­ers with­out tear­ing the skin proved near­ly impos­si­ble while wear­ing gloves, so I dis­card­ed mine ear­ly on. I found the small­er feath­ers eas­i­er to han­dle, their removal warm­ing my fin­gers against the chicken’s skin. The larg­er feath­ers, how­ev­er, released cold water with every hand­ful I pulled, and the mix of damp­ness and the autumn wind left my bare hands chilled to the bone.

The wind frus­trat­ed us all morn­ing as it whipped around the build­ing and dis­rupt­ed our dis­as­sem­bly line. At one point, it blew water from the machine pluck­er onto its cir­cuits, short­ing it out. Even before that mishap, the wind car­ried away the heat from the propane burn­er beneath our scald­ing pot. Maintaining the water at the ide­al tem­per­a­ture for the pluck­er was critical—it had to be just right. Too cool, and the pluck­er failed to work; too hot, and it tore through the chicken’s skin. And so, most of our birds emerged from the machine nei­ther ful­ly plucked nor skin whol­ly intact.

If the pluck­er had worked as intend­ed, per­haps it would have been worth the lump it induced in my throat. It seemed the most dis­con­nect­ed part of the pro­cess­ing. A pair of birds tum­bled quick­ly, loud­ly, and vio­lent­ly around a rub­ber-fin­ger-lined bar­rel, while a buck­et beneath the machine col­lect­ed a pink slur­ry of water, feath­ers, and blood. Someone sprayed water from a hose into the open bar­rel from a few feet away, after anoth­er class­mate flicked on the machine and ducked away. I avoid­ed these tasks.

Instead, I chose to wit­ness blood drain from the chick­ens. Graceful crim­son lines arced from the birds’ bod­ies to the col­lec­tion buck­et and beyond, car­ried on the same gusts that chilled our hands. The blood drained slow­ly, rely­ing on grav­i­ty rather than the rhythm of a beat­ing heart, as the birds’ bod­ies relaxed.

Moments before, I had pulled my knife across their necks. It felt like a small kind­ness — a way to hur­ry them into still­ness. I sur­prised myself at how calm­ly I pulled taught their skin, my glove cush­ion­ing their head to stop its swing­ing. It was clear that their skull wasn’t attached to the spine any­more, but I didn’t ful­ly believe Levi’s assur­ances that they were already dead.

The chick­ens kicked, flapped, and moved their beaks. Each one was different—some went gen­tly, oth­ers vio­lent­ly. Many stopped mov­ing after a few moments; oth­ers thrashed for what felt like min­utes. Tinny thumps echoed as feath­ers flailed against the gal­va­nized steel cones that con­tained them. Two of these spe­cial­ly designed pro­cess­ing restraints were nailed into a two-by-four frame. As one chick­en help­less­ly flexed its feet sky­ward, we fed anoth­er in, limp head dan­gling down, cradling its protest­ing wings into the sec­ond cone.

A mishap and a quick resolution

Levi had dis­patched most of the chick­ens, and the rest of the group was con­tent to focus on the more time-con­sum­ing tasks. Killing the birds was the quick­est part of the process. Levi pre­ferred “cer­vi­cal dis­lo­ca­tion,” a method that requires no tools and keeps both hands on the bird through­out. This approach helped avoid the very real pos­si­bil­i­ty of chas­ing chick­ens with their heads cut off across the Extension Office park­ing lot. For the sake of ani­mal wel­fare, Levi took on the task of dis­patch­ing well over half the chick­ens with deft skill.

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A few res­olute par­tic­i­pants still gave it a try. We were there to learn, and Levi under­stood that mis­takes were part of the process. Many birds were dis­patched quick­ly and clean­ly. Others, how­ev­er, were not so for­tu­nate. One gen­tle­man acci­den­tal­ly dis­lo­cat­ed a bird’s head clean off, while a woman ripped open the neck skin with­out actu­al­ly killing the bird.

That woman was me. Levi swift­ly end­ed the mis­ery I had unin­ten­tion­al­ly caused, lift­ing the bird from my hands with prac­ticed ease before I could answer his ques­tion: “Did you feel it pop?” I had fol­lowed the instructions—widening my arms and twist­ing my wrist as direct­ed. But pan­ic set in—the kind from nev­er hav­ing killed any­thing larg­er than a bug. 

“I need help” bub­bled out of me, as the pop I antic­i­pat­ed nev­er came. Perhaps my hands weren’t posi­tioned correctly—two fin­gers below her beak and a thumb at the base of her skull. Maybe I had placed my oth­er hand too far down her leg, my arm span too short to com­plete the task. Whatever the rea­son, I had failed her.

She hadn’t squawked or flapped. Instead, she lay calm­ly in my hands, warm and heavy, her white, scrag­gly feath­ers puffed out against the cold. Levi had lift­ed her from the yel­low plas­tic cages with bare­ly a protest, choos­ing her at ran­dom from the flock. 

I don’t know if she was the same hen that blinked up at me from the cages before the class began. None of the flock seemed dis­tressed. They cooed and rus­tled, hud­dling togeth­er against the wind. These birds were accus­tomed to life out­doors. For most of their thir­ty-six days, they had lived in a pas­ture at Southern Songbird Farm, just ten miles away. They clucked and chirped as farm­ers Doug and Carrie Shepperson brought them fresh grain and new grass. Every day, they feast­ed against a back­drop of late-sum­mer hills, their world earthy-green, bright and warm. 

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