Abstract:
A poultry part harvesting, sorting, and packaging apparatus and system utilizes an arrangement of hoppers to batch poultry parts removed by cut-up machines and deposits the batches onto a transportation conveyor. Each batch is contained within a separate zone on the conveyor, and the system tracks the location of batches and open spaces on the conveyor to deliver the batches to user defined locations.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority in of U.S. Provisional Patent Application No. 62/354,241, filed Jun. 24, 2016, the contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND 
     1. Field of the Disclosed Subject Matter 
       [0002]    The disclosed subject matter relates generally to animal processing, and more particularly to a method of distributing animal tissues harvested from animals within a processing facility. 
       2. Description of the Background Art 
       [0003]    Processing animals for consumption involves sequentially harvesting parts of the animal at a processing facility. The harvested tissues are transported on multiple conveyors within the processing facility for further processing and packaging. These conveyors systems can be large, complicated and have conveyors positioned so closely together that they are difficult to access and clean. 
       SUMMARY 
       [0004]    A poultry part harvesting, sorting, and packaging apparatus and method utilizes an arrangement of hoppers to batch poultry parts removed by cut-up machines and deposits the batches onto a transportation conveyor for distribution to packaging, increasing the speed of animal processing and accuracy of the packaged product. 
         [0005]    An embodiment of the disclosed subject matter includes a poultry processing system including a first machine for removing poultry parts from a poultry carcass, a first hopper for receiving the poultry parts from the first machine, a conveyor for receiving poultry parts from the first hopper, the conveyor defining a first zone for receiving the poultry parts, and a data processing system including a processor, a first input device, and a first output device. The first input device includes a weight sensor configured to detect the weight of the poultry parts within the first hopper, and the weight sensor configured to provide weight data to the processor. The first output device configured to deposit the poultry parts onto the conveyor. The data processing system is configured to control movement of the output device and conveyor, and the system deposits the poultry parts of the first hopper within the first zone upon the weight of the poultry parts within the first hopper achieving a threshold weight. 
         [0006]    In an aspect of the embodiment, the first zone moves relative to the first hopper, and the data processing system tracks the location of the first zone. In an aspect, the poultry processing system includes a first bulk container, and the first zone is moved to, and the poultry parts deposited in, the first bulk container. In an aspect, the poultry processing system includes a first box container, and the first zone is moved to, and the poultry parts deposited in, the first box container. In another aspect, the poultry processing system includes a bottom wall movable connected to the first hopper, and the first output device is an actuator operably connected to the bottom wall for moving the bottom wall to deposit poultry parts onto the conveyor. In an aspect of the embodiment, the poultry processing system includes an overhead conveyor for delivering the poultry carcasses to the first machine. 
         [0007]    In an aspect, the first input device is a weight sensor configured to detect the weight of the poultry parts within the first hopper and provide weight data to the processor, and the system deposits the poultry parts of the first hopper within the first zone upon the weight of the poultry parts within the first hopper achieving a threshold weight. 
         [0008]    In an aspect, the first input device is a count mechanism configured to count the poultry parts within the first hopper and provide count data to the processor, and the system deposits the poultry parts of the first hopper within the first zone upon the count of the poultry parts within the first hopper achieving a threshold count. 
         [0009]    An embodiment of the disclosed subject matter includes a poultry processing method including the steps of providing a plurality of machines for removing poultry parts from a poultry carcass, providing a hopper for each machine, the hopper configured to receive the poultry parts from the machine, providing a transportation conveyor for receiving poultry parts from the hoppers, the transportation conveyor defining a plurality of zones for receiving poultry parts, and providing a data processing system comprising a processor operably connected to a plurality of input devices and a plurality of output devices. The input devices include measuring devices configured to detect the amount of the poultry parts within each of the hoppers, the measuring devices configured to provide poultry part amount data to the processor. The output devices are configured to deposit the poultry parts from the hoppers in batches onto the transportation conveyor. The data processing system is provided with poultry part amount data, is configured to control the output device and transportation conveyor, and the system deposits the poultry parts within a zone on the transportation conveyor upon the weight of the poultry parts within a hopper achieving a threshold amount. 
         [0010]    In an aspect of the embodiment, the poultry processing method, the plurality of machines include cut-up stations, and the plurality of hoppers include a mid joints hopper, a drumettes hopper, a whole wings hopper, a boneless thighs hopper, a breast caps hopper, a split breasts hopper, a breast fillets hopper, a tenders hopper, a leg quarters hopper, an anatomical legs hopper, a spatchcock hopper, a drums hopper, and a bone in thighs hopper. 
         [0011]    In an aspect, the poultry processing method includes providing a first distribution line, including a first conveyor system conveying poultry carcasses to a cut-up station and hopper for mid joints, drumettes, whole wings, and boneless thighs, a second conveyor system conveying poultry carcasses to a cut-up station and hopper for mid joints, drumettes, boneless thighs, and breast caps, and a third conveyor system conveying poultry carcasses to a cut-up station and hopper for drumettes, mid joints, boneless things, and split breasts. The poultry parts are deposited onto the transportation conveyor from the hoppers according to the sequence of first conveyor boneless thighs, second conveyor boneless thighs, third conveyor boneless thighs, second conveyor breast caps, third conveyor split breasts, first conveyor mid joints, first conveyor drumettes, first conveyor whole wings, first conveyor boneless thighs, second conveyor boneless thighs, third conveyor boneless thighs, second conveyor breast caps, third conveyor split breasts, second conveyor mid joints, second conveyor drumettes, first conveyer whole wings, first conveyor boneless thighs, second conveyor boneless thighs, third conveyor boneless thighs, second conveyor breast caps, third conveyor split breasts, third conveyor mid joints, and third conveyor drumettes. 
         [0012]    In an aspect, the poultry processing method includes providing a second distribution line, including a first conveyor system conveying poultry carcasses to a cut-up station and hopper for breast fillets, tenders, leg quarters, and anatomical legs, a second conveyor system conveying poultry carcasses to a cut-up station and hopper for breast fillets, tenders, spatchcock, and leg quarters, and a third conveyor system conveying poultry carcasses to a cut-up station and hopper for breast fillets, tenders, and leg quarters. The poultry parts are deposited onto the transportation conveyor from the hoppers according to the sequence of first conveyor leg quarters, first conveyor anatomical legs, first conveyor breast fillets, second conveyor leg quarters, second conveyor spatchcock, second conveyor breast fillets, third conveyor leg quarters, third conveyor breast fillets, first conveyor tenders, first conveyor leg quarters, first conveyor anatomical legs, first conveyor breast fillets, second conveyor leg quarters, second conveyor spatchcock, second conveyor breast fillets, third conveyor leg quarters, third conveyor breast fillets, second conveyor tenders, first conveyor leg quarters, first conveyor anatomical legs, first conveyor breast fillets, second conveyor leg quarters, second conveyor spatchcock, second conveyor breast fillets, third conveyor leg quarters, third conveyor breast fillets, and second conveyor tenders. 
         [0013]    In an aspect, the poultry processing method includes providing a third distribution line, including a first conveyor system conveying poultry carcasses to a cut-up station and hopper for first drums, second drums, and bone in thighs, a second conveyor system conveying poultry carcasses to a cut-up station and hopper for first drums, second drums, and bone in thighs, and a third conveyor system conveying poultry carcasses to a cut-up station and hopper for first drums, second drums, and bone in thighs. The poultry parts are deposited onto the transportation conveyor from the hoppers according to the sequence of first conveyor first conveyor bone in thighs, first conveyor first conveyor first drums, first conveyor second drums, second conveyor bone in thighs, second conveyor first drums, second conveyor second drums, third conveyor bone in thighs, third conveyor first drums, third conveyor bone in thighs, first conveyor bone in thighs, first conveyor first drums, first conveyor second drums, second conveyor bone in thighs, second conveyor first drums, second conveyor second drums, third conveyor bone in thighs, third conveyor first drums, third conveyor bone in thighs, first conveyor bone in thighs, first conveyor first drums, first conveyor second drums, second conveyor bone in thighs, second conveyor first drums, second conveyor second drums, third conveyor bone in thighs, third conveyor first drums, and third conveyor bone in thighs. 
         [0014]    In an aspect of the poultry processing method the measuring device is a weight sensor configured to detect the weight of the poultry parts within each of the hoppers, and provide weight data to the processor. 
         [0015]    In an aspect of the poultry processing method the measuring device is a count mechanism configured to count the poultry parts within each of the hoppers, and provide count data to the processor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The present disclosed subject matter is described herein with reference to the following drawing figures, with greater emphasis place on clarity rather than scale: 
           [0017]      FIG. 1  is a flow diagram showing process steps performed according to an embodiment of the disclosed subject matter. 
           [0018]      FIG. 2  is a block diagram of an embodiment of a data processing system operable with the disclosed subject matter. 
           [0019]      FIG. 3  is a block diagram of an embodiment of a control system operable with the disclosed subject matter. 
           [0020]      FIG. 4  is a diagram showing the conveyor system and cut-up stations embodying aspects of the disclosed subject matter. 
           [0021]      FIG. 5  is a diagram representing structures and functions of the conveyor system, cut-up stations, and hoppers embodying aspects of the disclosed subject matter. 
           [0022]      FIG. 6  is a flowchart diagramming an aspect of the steps of filling and emptying a hopper of the disclosed subject matter. 
           [0023]      FIG. 7  is a flowchart diagramming an aspect of the steps of filling and emptying a hopper of the disclosed subject matter. 
           [0024]      FIG. 8  is a diagrammatic representation of a first distribution line. 
           [0025]      FIG. 9  is a diagrammatic representation of a second distribution line. 
           [0026]      FIG. 10  is a diagrammatic representation of a third distribution line. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    The method of distributing animal tissues harvested from animals involves gathering like parts from a processing machine in bulk and depositing a batch of the parts at a specific location on a conveyor. 
         [0028]    In an embodiment of the disclosed subject matter, poultry carcasses move through a processing system  100  and pass through a series of poultry processing machines that remove parts from the poultry carcass. 
         [0029]    The disclosed technology includes apparatuses and methods for the processing of poultry carcasses. A broad overview of an embodiment of the disclosed processing system will be followed by a more detailed discussion of the processing system and associated apparatuses and components. 
         [0030]    Overview of the Poultry Processing System 
         [0031]      FIG. 1  is a flow diagram representing the general process steps of the poultry processing system  100 . The processing system  100  includes mechanical components that interface with data processing systems  400  and a control system  500 . Accordingly, the associated processing steps relate thereto. The poultry processing system  100  includes a continuous conveyor system  102  that transports poultry carcasses through one or more cut-up stations  104  where poultry parts are harvested from the carcasses. The cut-up stations  104  are arranged in a series beneath the conveyor system  102 , and each cut-up station  104  includes the appropriate mechanical hardware to harvest a particular poultry part from the carcass. The harvested poultry parts include the whole wing, wing tip, mid-wing, drumettes, two-joint wing without the tip, mid-wing with the tip, front half without wings, whole leg, drumstick, boneless thigh, breast caps, split breasts, breast fillets, tenders, leg quarters, anatomical legs, spatchcock, and bone in thighs. A hopper  106  below each cut-up station  104  collects, weighs, and retains the poultry parts as a batch until the control system  500  deposits the accumulated poultry parts on the transportation conveyor  107 . Once deposited on the transportation conveyor  107 , the control system  500  determines what batches move to processing for bulk container packaging  108  or processing for box container packaging  110 . 
         [0032]    The processing system  100  includes one or more cut-up stations  104  and hoppers that deposit batches of poultry parts onto a transportation conveyor  107 . The transportation conveyor  107  transports the batched poultry parts to bulk container packaging processing  108  or to box container packaging processing  110 . The physical layout of the poultry processing facility may: limit the number of cut-up stations  104 ; the physical arrangement of cut-up stations  104 ; and the route of the conveyor system  102 . Therefore, the mechanical components of the processing system  100  can be modified to accommodate the physical layout of the poultry processing facility. 
         [0033]    Overview of the Data Processing System &amp; Control System 
         [0034]    Events occurring during operation of the conveyor system  102 , cut-up stations  104 , bulk container packaging processing  108 , and box container packaging processing  110  affect the processing of the poultry parts at various steps throughout the processing system  100 . The aforementioned events are detected by input devices  406  that interface with the mechanical components of the poultry processing system  100 . The input devices  406  generate output data that is received by a plurality of data processing systems  400  that in turn generate output data to output devices  408  providing operative control of the aforementioned mechanical components. The control system  500  may receive input data from a plurality of data processing systems  400  located throughout the poultry processing system  100  for controlling the mechanical components of the system  100  and the overall processing of the poultry carcasses and poultry parts. 
         [0035]      FIG. 2  is a block diagram illustrating an embodiment of a data processing system  400  upon which an embodiment of the disclosed subject matter may be implemented. The system  400  may be a mobile device or a stand-alone device connected to the input devices  406  and output devices  408  throughout the system  100 . The system  400  includes an enclosure that protects the interior components from physical damage. 
         [0036]    Operation of the system  400  may be controlled by a processor  402  that executes the operating system, programs, and any other functions of the system  400  including processing data signals received from the input devices  406  and communicating data signals to output devices  408 . The system  400  may include one or more databases  430  for storing or transferring data and instructions between components of the system  400 . 
         [0037]    The processor  402  may comprise a single processor or a plurality of processors such as any conventional processor device known in the art, including other processors that enable various functions of the system  400  such as graphical user interface (GUI) functions, input devices  406 , and output devices  408 . 
         [0038]    Data, information, and instructions processed by the processor  402  may be stored within the program memory  410 . Data includes threshold data. The threshold data includes a threshold amount, such as a threshold weight or a threshold number or count amount. Program memory  410  may include non-volatile memory such as a dynamic storage device, random-access memory (RAM)  412 , read-only memory (ROM)  414 , flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state computer readable media, as well as a combination thereof, all of which are connected to the bus  404 . 
         [0039]    A storage device  416 , including a magnetic disk, optical disk, magneto-optical disk, or non-volatile memory for storing data, information, and instructions may be connected to the bus  404 . 
         [0040]    The system  400  may be powered by a suitable power source  418  that may include one or more batteries or an AC power source, such as provided by an electrical outlet. 
         [0041]    A user may input data, information, and/or instructions into the data processing system  400  using an input device  406  including: alphanumeric and other keys; a cursor control, such as a mouse, trackball, or cursor direction keys; and any number of input structures existing in various forms including sensors, buttons, switches, control pad, knob, wheel, or other suitable forms. 
         [0042]    System  400  information and images are presented by a display  420 . For example, the display  420  may show system  400  information and images including operational status of the distribution and packaging line, distribution and packaging lines with their products, and desired final output of poultry parts for customer orders. The display  420  may be any type of display, such as a cathode ray tube (CRT), a liquid crystal display (LCD), a light emitting diode (LED) display, an organic light emitting diode (OLED) display, or other suitable display. The display  420  may include touch-sensitive functionality, such as a touch screen. The display  420  may display a GUI that allows a user to interact with the system  400 . The GUI may include various screens, layers, windows, elements, or components that may be displayed in whole or in part on all or a portion of the display  420 . 
         [0043]    In an embodiment of the disclosed subject matter, aspects of the processing system  100  are performed by a local data processing system  400  in response to the processor  402  executing one or more sequences of one or more instructions contained in the program memory  410 . Such instructions may be read into the program memory  410  from another computer-readable medium, including the storage device  416 . Execution of the sequences of instructions contained in the program memory  410  cause the processor  402  to perform the process steps described herein. In alternative embodiments, a plurality of data processing systems  400  may be used in combination with a control system  500  executing one or more sequences of one or more instructions. 
         [0044]    One or more communication interfaces  422  may provide additional data channels for receiving and transmitting data, information, or instructions. The communication interface  422  may include one or more network interface hardware elements and associated communication protocols. The communication interface  422  provides two-way data communication by a network connection  424  connected to a local network  426 . The communication interface  422  may include several types of interfaces, including a wireless local area network (WLAN) interface, and unstructured supplementary service data (USDD) interface, a personal area network (PAN) interface, a local area network (LAN) interface, and a wide area network (WAN) interface. 
         [0045]    The network connection  424  also provides a data connection through one or more local networks  426  to other data devices by a data connection  428 . For example, the network connection  424  may also provide a connection through a LAN  426  to other data processing systems  400  used in the poultry processing system  100 , or to the control system  500 . The data processing system  400  may execute one or more sequences of one or more instructions contained in one or more databases  430  connected to the local network  426 . 
         [0046]    Referring to  FIG. 3 , the control system  500  includes many of the same components found in the data processing system  400  serving similar functions. In addition, the control system  500  analyzes events occurring during poultry processing in the form of data from the various data processing systems  400  and adjusts operation of the processing system  100  and movement of the poultry parts through the processing system  100  to optimize the distribution of the poultry parts throughout, and to avoid a cessation of movement of poultry parts through the processing system  100 . 
         [0047]    Event data may include: mechanical problems with the bulk container packaging processing  108 ; mechanical problems with the box container packaging processing  110 ; a backup of movement of poultry parts through the bulk container packaging processing  108 ; a backup of movement of poultry parts through the box container packaging processing  110 ; and a determination by the control system  500  that carcasses or poultry parts in the processing system  100  have characteristics that dictate their processing by bulk container packaging processing  108  or box container packaging processing  110 . The data processing system  400  can determine batch and product composition, configuration of each distribution and packing line, and final destination of each batch and product to fill customer orders based on the incoming batches or product (fully automated) or it could display the configuration of each distribution and packing line, incoming carcasses and product to be processed and batches and products required to fill orders and allow the user to determine each product&#39;s destination (partially automated). 
         [0048]    Conveyor System &amp; Poultry Part Harvesting 
         [0049]    Poultry carcasses are delivered to the various cut-up stations  104  by an overhead conveyor system  102 . A hopper  106  below each cut-up station  104  collects, weighs, and retains the poultry parts harvested by the cut-up station  104  above as a batch until a processing parameter dictates a drop of the contents of the hopper  106 . A plurality of input devices  406  interface with a plurality of data processing systems  400  and a control system  500  to store and analyze event data generated by the poultry processing system  100 . 
         [0050]    Referring to  FIG. 4 , the processing system  100  is shown from above with the conveyor system  102  moving in the direction of arrow  202  over a plurality of aligned cut-up stations  104 , represented by cut-up stations  204   a,    204   b,  and  204   c . Although only three cut-up stations  104  are shown, the system  100  can include additional cut-up stations  104 . Each cut-up station  104  includes a mechanical processing device that removes a poultry part from the carcass, described above. The conveyor system  102  travels throughout the processing facility to guide the poultry carcasses through the cut-up stations  104  wherever they are located. In an alternative embodiment, cut-up stations  104  may be curvilinear aligned along a transportation conveyor  107  to accommodate the desired layout of the processing system  100  within a processing facility. 
         [0051]    Referring to  FIG. 5 , an embodiment of the conveyor system  102  is represented showing poultry carcasses suspended from the conveyor system  102 , represented by poultry carcasses  502   a,    502   b,  and  502   c  passing through cut-up station  204   b.  The conveyor system  102  includes trollies  206  that move along a track  208 . The trollies  206  include wheels rotatably mounted to a frame for rolling along the track  208 . A plurality of trollies  206  may be interconnected by connectors, and a motive force may be operably connected to the trollies  206  or connectors for advancing the carcasses through the processing system  100 . 
         [0052]    The poultry carcasses  502   a,    502   b,  and  502   c  are suspended by their legs from shackles  210   a,    210   b,  and  210   c,  respectively. Each shackle is connected to the trolley  206  and suspended below the track  208  by a suspension device  212   a,    212   b,  and  212   c.  Suspension of the carcass from a shackle above the cut-up stations  104  allows the carcass to be manipulated and orientated by each cut-up station  104  for removal of a particular poultry part. 
         [0053]    The hopper  106 , represented by hopper  218   b  includes side walls defining an inlet  220  for receiving poultry parts  504  from the cut-up station  204   b,  and an outlet  222  for depositing the contents on the transportation conveyor  107 . A movable portion of the hopper  218   b  retains the poultry parts  504  within the hopper  218   b.  An output device  408 , represented by one or more actuators  226 , is operably connected to a portion of the hopper  218   b,  such as a bottom wall, side wall, or doors  219  for moving the door  219 . In an implementation, the actuator  226  is pneumatically powered, hydraulically powered, or electrically powered. 
         [0054]    The poultry parts  504  are measured as they accumulate in the hopper  218   b.  The amount of poultry parts  504  within the hopper  218   b  are measured by an input device  406 . In an implementation, the input device  406  is a measuring device  224 . Other input devices  406  used with the system  100  include a level sensor to measure the level of the poultry parts in the hopper  218   b,  a proximity sensor to detect when the volume of poultry parts in the hopper  218   b  achieve a pre-determined level, and a product count mechanism that counts the number of poultry parts as they move from the cut-up station  104  to the hopper  218   b.  In an implementation, the product count mechanism includes a moment switch or a limit switch that is activated as the poultry parts pass by and engage the switch. In an implementation, the measuring device  224  is a weight sensor, such as a load cell, configured to provide weight data to the processor  402 . Although load cells are described, the sensors used with the hopper  218   b  may include any conventional means of determining the contents of the hopper  218   b,  including photo recognition, and radar with poultry part counting and size algorithms. The measuring device  224  generates an output signal, represented by dashed line  216   b.  In the described implementations, the output signal  216   b  of the weight sensor is event data that represents the weight of the contents of the hopper  218   b  and the output signal  216   b  of the count mechanism is event data that represents one or more poultry parts. The signal  216   b  is transmitted to the data processing system  400 , represented by the data processing system  238 . The system  238  analyzes the signal along with other event data received from throughout the system  100 . 
         [0055]      FIG. 6  is a flowchart of an exemplary poultry processing method including hopper  106 , such as hopper  218   b,  comprising an aspect of the disclosed subject matter. As poultry parts  504  accumulate in the hopper  218   b,  the weight of the contents of the hopper  218   b  is detected by the weight sensor, and the weight is monitored by the data processing system  238 . The poultry parts  504  fill the hopper at step  598  and accumulate in the hopper  218   b  until the weight reaches a predetermined threshold level wherein the system  238  determines a drop for the batch to deposit the poultry parts  504  on the transportation conveyor  107 . At step  600  the data processing system  238  analyzes the weight of the hopper  218   b.  At step  602  the data processing system  238  calculates and measures the weight of the hopper  218   b,  and at step  602  compares the measured weight of the hopper  218   b  to the pre-determined threshold weight. If the measured weight has not reached the pre-determined weight, at step  604  the hopper  218   b  retains the batch. As poultry parts  504  further accumulate in the hopper  218   b  the data processing system  238  at step  600  reanalyzes the weight of the hopper  218   b.  The drop of a batch is determined by event data including characteristics of the poultry parts  504  in the hopper  218   b,  a backup in the processing of poultry parts downstream from the hopper  218   b,  and the availability of a space for the batch on the transportation conveyor  107 . The data processing system  238  is configured to control movement of the transportation conveyor  107 . When the measured weight has reached the pre-determined weight, at step  606  the data processing system  238  determines if there is space available on the conveyor  107 . As the transportation conveyor  107  moves in the direction of arrow  112 , it may have a first batch  122  of poultry parts upstream on the conveyor  107  moving toward the hopper  218   b,  followed by a first open space  124 , and followed by a second batch  126 . Poultry parts of different types can share the same conveyor  107 . The system  238  tracks the location of each batch deposited on the conveyor  107  and the hopper  218  that deposited the batch allowing the system  238  to track the location of the open and occupied spaces on the conveyor  107 . The system  238  tracks the location of these spaces or zones as they move through the steps of the processing system  238 . The system  238  tracks and controls conveyor  107  speed, batch location, and batch spacing. The system  238  knows the location of the zones on the conveyor  107  allowing the system to avoid mixing of batches of dissimilar poultry parts, allowing the system to transport the batches of poultry parts on one conveyor to bins for further processing. If a space is not available on the conveyor  107 , at step  608  the system  100  holds the batch in the hopper  218   b,  awaiting an open space on the conveyor  107 . If a space is available on the conveyor  107 , at step  610  the system  238  deposits the batch onto the conveyor  107 . The system  238  sends an actuator output signal, represented by dashed line  216   c,  to the actuator  226  to release the contents of the hopper  218   b  on the conveyor  107 . At step  612  the system  238  logs the location or zone of the batch on the conveyor  107  and the type of poultry parts and weight, the batch proceeds downstream for further processing, and the outlet  219  is sealed and the process of filling the hopper  218   b  begins again. 
         [0056]      FIG. 7  is a flowchart of an exemplary poultry processing method including hopper  106 , such as hopper  218   b,  comprising an aspect of the disclosed subject matter. As poultry parts  504  accumulate in the hopper  218   b,  the number of poultry parts  504  within the hopper  218   b  is counted by the a count mechanism, and the amount is monitored by the data processing system  238 . The poultry parts  504  fill the hopper at step  598  and accumulate in the hopper  218   b  until the count reaches a predetermined threshold level wherein the system  238  determines a drop for the batch to deposit the poultry parts  504  on the transportation conveyor  107 . At step  620  the data processing system  238  counts the number of poultry parts within the hopper  218   b . At step  622  the data processing system  238  calculates the number of poultry parts within the hopper  218   b,  and at step  622  compares the count within the hopper  218   b  to the pre-determined threshold count. If the measured count has not reached the pre-determined count, at step  604  the hopper  218   b  retains the batch. As poultry parts  504  further accumulate in the hopper  218   b  the data processing system  238  at step  620  reanalyzes the count of the hopper  218   b.  The drop of a batch is determined by event data including characteristics of the poultry parts  504  in the hopper  218   b,  a backup in the processing of poultry parts downstream from the hopper  218   b,  and the availability of a space for the batch on the transportation conveyor  107 . The data processing system  238  is configured to control movement of the transportation conveyor  107 . When the measured count has reached the pre-determined count, at step  606  the data processing system  238  determines if there is space available on the conveyor  107 . As the transportation conveyor  107  moves in the direction of arrow  112 , it may have a first batch  122  of poultry parts upstream on the conveyor  107  moving toward the hopper  218   b,  followed by a first open space  124 , and followed by a second batch  126 . Poultry parts of different types can share the same conveyor  107 . The system  238  tracks the location of each batch deposited on the conveyor  107  and the hopper  218  that deposited the batch allowing the system  238  to track the location of the open and occupied spaces on the conveyor  107 . The system  238  tracks the location of these spaces or zones as they move through the steps of the processing system  238 . The system  238  tracks and controls conveyor  107  speed, batch location, and batch spacing. The system  238  knows the location of the zones on the conveyor  107  allowing the system to avoid mixing of batches of dissimilar poultry parts, allowing the system to transport the batches of poultry parts on one conveyor to bins for further processing. If a space is not available on the conveyor  107 , at step  608  the system  100  holds the batch in the hopper  218   b , awaiting an open space on the conveyor  107 . If a space is available on the conveyor  107 , at step  610  the system  238  deposits the batch onto the conveyor  107 . The system  238  sends an actuator output signal, represented by dashed line  216   c,  to the actuator  226  to release the contents of the hopper  218   b  on the conveyor  107 . At step  612  the system  238  logs the location or zone of the batch on the conveyor  107  and the type of poultry pars and count, the batch proceeds downstream for further processing, and the outlet  219  is sealed and the process of filling the hopper  218   b  begins again. 
         [0057]    In an embodiment of the disclosed subject matter, the processing system  100  includes a plurality of cut-up stations  104 , and associated hoppers  106  beneath the cut-up stations  104  that drop batches of poultry parts onto a transportation conveyor  107  in a defined sequence. Referring to  FIGS. 8-10 , a first distribution line  152 , second distribution line  164 , and third distribution line  170  work in tandem to distribute batches of poultry parts onto a transportation conveyor  107 . One or more conveyor systems  102  move poultry carcasses through the cut-up stations  104 . Each cut-up station  104  removes a poultry part from the poultry carcass. Each station  104  has an associated hopper  106  gathering the poultry part removed by the associated cut-up station  104 . Each hopper  106  gathers one of: mid joints  652 , drumettes  654 , whole wings  656 , boneless thighs  658 , breast caps  660 , split breasts  662 , breast fillets  664 , tenders  666 , leg quarters  668 , anatomical legs  670 , spatchcock  672 , drums  674 ,  675 , or bone in thighs  676 . 
         [0058]    Referring to  FIG. 8 , a plurality of cut-up stations  104  feed a plurality of hoppers  106  arranged along the first distribution line  152 , the first distribution line  152  feeding batches to a transportation conveyor  107 . The first distribution line  152  includes cut-up stations and hoppers for mid joints  652 , drumettes  654 , whole wings  666 , boneless thighs  658 , breast caps  660 , and split breasts  662 , fed by three conveyor systems  102 . 
         [0059]    In an implementation, the hoppers  106  of the first distribution line  152  deposit batches of poultry parts onto the transportation conveyor  107  in a first sequence. A first conveyor system  102   a  feeds hoppers for mid joints  652   a,  drumettes  654   a,  whole wings  656   a,  and boneless thighs  658   a.  A second conveyor system  102   b  feeds hoppers for mid joints  652   b,  drumettes  654   b,  boneless thighs  658   b,  and breast caps  660   b.  A third conveyor system  102   c  feeds hoppers for drumettes  654   c,  mid joints  652   c,  boneless things  658   c,  and split breasts  662   c.  The first sequence includes a first minute, followed by a second minute, followed by a third minute. The first minute includes eight sequential drops from different batches. The sequential drops are boneless thighs  658   a , boneless thighs  658   b,  boneless thighs  658   c,  breast caps  660   b,  split breasts  662   c,  mid joints  652   a,  drumettes  654   a,  and whole wings  656   a.  The second minute includes seven drops from different batches. The sequential drops are boneless thighs  658   a,  boneless thighs  658   b,  boneless thighs  658   c,  breast caps  660   b,  split breasts  662   c,  mid joints  652   b , and drumettes  654   b.  The third minute includes eight drops from different batches. The sequential drops are whole wings  656   a,  boneless thighs  658   a,  boneless thighs  658   b , boneless thighs  658   c,  breast caps  660   b,  split breasts  662   c,  mid joints  652   c,  and drumettes  654   c.  Upon completion of the third minute, the system  100  returns to the first minute and cycles through again. 
         [0060]    Referring to  FIG. 9 , a plurality of cut-up stations  104  feed a plurality of hoppers  106  arranged along the second distribution line  164 , the second distribution line  164  feeding batches to the transportation conveyor  107 . The second distribution line  164  includes cut-up stations and hoppers for breast fillets  664 , tenders  666 , leg quarter  668 , anatomical legs  670 , and spatchcock  672 , fed by three conveyor systems  102 . 
         [0061]    In an implementation, the hoppers  106  of the second distribution line  164  deposit batches of poultry parts onto the transportation conveyor  107  in a first sequence. The first conveyor system  102   a  feeds hoppers for breast fillets  664   a,  tenders  666   a,  leg quarters  668   a,  and anatomical legs  670   a.  The second conveyor system  102   b  feeds hoppers for breast fillets  664   b,  tenders  666   b,  spatchcock  672   b,  and leg quarters  668   b . The third conveyor system  102   c  feeds hoppers for breast fillets  664   c,  tenders  666   c,  and leg quarters  668   c.  The first sequence includes a first minute, followed by a second minute, followed by a third minute. The first minute includes nine sequential drops from different batches. The sequential drops are leg quarters  668   a,  anatomical legs  670   a,  breast fillets  664   a,  leg quarters  668   b,  spatchcock  672   b,  breast fillets  664   b,  leg quarters  668   c,  breast fillets  664   c,  and tenders  666   a.  The second minute includes nine drops from different batches. The sequential drops are leg quarters  668   a,  anatomical legs  670   a,  breast fillets  664   a,  leg quarters  668   b,  spatchcock  672   b,  breast fillets  664   b , leg quarters  668   c,  breast fillets  664   c,  and tenders  666   b.  The third minute includes nine drops from different batches. The sequential drops are leg quarters  668   a,  anatomical legs  670   a,  breast fillets  664   a,  leg quarters  668   b,  spatchcock  672   b,  breast fillets  664   b , leg quarters  668   c,  breast fillets  664   c,  and tenders  666   b.  Upon completion of the third minute, the system  100  returns to the first minute and cycles through again. 
         [0062]    Referring to  FIG. 10 , a plurality of cut-up stations  104  feed a plurality of hoppers  106  arranged along the third distribution line  170 , the third distribution line  170  feeding batches to the transportation conveyor  107 . The third distribution line  170  includes cut-up stations and hoppers for first drums  674 , second drums  675 , and bone in thighs  676 , fed by three conveyor systems  102 . 
         [0063]    In an implementation, the hoppers  106  of the third distribution line  170  deposit batches of poultry parts onto the transportation conveyor  107  in a first sequence. The first conveyor system  102   a  feeds hoppers for first drums  674   a,  second drums  675   a , and bone in thighs  676   a.  The second conveyor system  102   b  feeds hoppers for first drums  674   b,  second drums  675   b,  and bone in thighs  676   b.  The third conveyor system  102   c  feeds hoppers for first drums  674   b,  second drums  675   b,  and bone in thighs  676   b . The first sequence includes a first minute, followed by a second minute, followed by a third minute. The first minute includes nine sequential drops from different batches. The sequential drops are bone in thighs  676   a,  first drums  674   a,  second drums  675   a , bone in thighs  676   b,  first drums  674   b,  second drums  675   b,  bone in thighs  676   c,  first drums  674   c,  and bone in thighs  675   c.  The second minute includes nine sequential drops from different batches. The sequential drops are bone in thighs  676   a,  first drums  674   a,  second drums  675   a,  bone in thighs  676   b,  first drums  674   b,  second drums  675   b , bone in thighs  676   c,  first drums  674   c,  and bone in thighs  675   c.  The third minute includes nine sequential drops from different batches. The sequential drops are bone in thighs  676   a,  first drums  674   a,  second drums  675   a,  bone in thighs  676   b,  first drums  674   b,  second drums  675   b,  bone in thighs  676   c,  first drums  674   c,  and bone in thighs  675   c.  Upon completion of the third minute, the system  100  returns to the first minute and cycles through again. 
         [0064]    The batches from the drops from the distribution lines  152 ,  164 , and  170  travel to bulk container packaging processing  108  or to box container packaging processing  110  for further processing. In an embodiment, the system  100  transports the poultry parts to bulk containers  114  instead of bulk container packaging processing  108  or to box container packaging processing  110 . Bulk containers  114  are then stored in refrigeration and the poultry parts are reintroduced to the transportation conveyor  107  as needed for transportation to bulk container packaging processing  108  or to box container packaging processing  110 . 
         [0065]    In an embodiment, the system  100  includes a yield measuring system that influences cut-up, batching, and distribution. In an embodiment, the system  100  includes a quality control system. 
         [0066]    As required, detailed aspects of the disclosed subject matter are disclosed herein; however, it is to be understood that the disclosed aspects are merely exemplary of the disclosed subject matter, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the disclosed technology in virtually any appropriately detailed structure. For purposes of clarity in illustrating the characteristics of the present disclosed subject matter, proportional relationships of the elements have not been maintained in the figures. In some cases, the sizes of certain small components have been exaggerated for illustration.