Abstract:
A colony basket and method of using the same for handling poultry from DOC through the growing process and on to a production facility comprising a harvesting system, a loading system, a transport system, an unloading and storing system, hanging system and cleaning system. The system and method performs the steps of harvesting and colonizing live poultry into a singly stackable and transportable colony basket, stacking and loading the trays on a transport, unloading and temporarily storing the poultry for subsequent processing. The system and method further includes the use of a modular colony basket for interchangeable use with the described system.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of Ser. No. 14/243,443 filed Apr. 2, 2014; said application Ser. No. 14/243,443 is a continuation-in-part of U.S. patent application Ser. No. 13/777,767 filed Feb. 26, 2013 and issued as U.S. Pat. No. 9,119,382 entitled Portable Basket Colony for Growing and Transport and Method of Use; the entire disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF INVENTION 
     Field 
     The field relates generally to poultry processing and more particularly to handling, growing and transporting live poultry. 
     Background Art 
     Loading and unloading birds and transportation of live birds from the hatchery stage through the kill stage at a production facility is a challenging task. The birds have to be gathered, contained and transferred to a transport means and subsequently unloaded with minimal damage or harm to the animal, which is challenging because birds instinctively resist such movement. For example, transport of live poultry from the hatchery to growing houses and from growing houses to processing facilities is required. One method of transport of live poultry is containing the birds in cages and stacking the cages on a truck with a flatbed trailer for transport. Loading and unloading trailers with live animals, particularly from a location where the animals are grown or raised to a processing facility, can in the case of chickens, increase the stress level of the animal. With heightened stress, animals are more likely to have increased body temperature, experience bruising, dislocated wing/leg joints and potential tissue damage along with an increased pH level, which may affect the quality of the muscle. Once the birds are captured in cages, the cages must be loaded on the trailer. 
     Existing systems involve crews of catchers to unload the birds from the growing colonies and load them for transport means. Loading of the cages on the trailer consumes the full time of one operator to move cages from the house or growing area to the trailer and it requires skill to stack cages on the trailer so that they can be properly secured for transport. The cages often become damaged in this operation over time and need to be repaired and eventually replaced. Damage to the cages often involves the doors through which the birds are inserted. Poorly operating doors leads to increased time to load cages and potential bird damage. 
     There are significant labor issues because it is very labor intensive and requires some level of skill and training. There are health issues for both the birds and the handlers. The labor intensive handling of the birds promotes infections of the handler and risks harm to the birds. This results in numerous health and safety concerns. The cages are prone for damage which can cause bird damage and extensive time and labor is utilized to fill the cages with birds and load and secure them for transport. The cages or other transport containers also have to be cleaned prior reuse, which can also be a labor intensive and costly effort. 
     Loading of poultry is a cumbersome and time consuming task. In the catching process, the poultry are placed into cages. Some cage designs consist of “drawers” and can vary from 10 to 15 drawers averaging a 20-25 bird capacity per drawer. Birds can be placed into the cages either manually or by semi-automatic means. A forklift then can load a flatbed truck with 18-22 cages that are stacked in pairs. Once the cages are in place, each stack has to be secured by chains to the frame of the trailer. 
     Semi-automated methods of harvesting the birds in the houses have encountered mechanical and functional problems. In one sense this semi-automated method eliminates the need for operators to physically pick up the birds. However, operators are still needed to operate the equipment and to move the birds forward and away from the sides of the house. Therefore, some handling is still necessary. 
     Plastic poultry trays or drawers are sometimes used to transport and house birds temporarily, however, these systems are temporal and only used during certain stages and are not integral with growing systems or transport systems. Use of such trays or drawers still require significant handling of birds, though they may be somewhat more durable than metal cages. Further, these plastic poultry trays, though less often than the standard cages, are also subject to damage or breakage resulting in a need to replace the entire tray, even though only one area of the tray may be cracked or otherwise damaged. The plastic trays are likely easier to clean and sanitize than the standard cage but given the size of the typical plastic tray and the webbing of the mesh, they also can be difficult to clean. Also, storing trays when they are not in use can consume a large amount of space. 
     As noted above, problems occur with, loading, unloading, harvesting, placing birds into cages (plastic drawers or trays), loading the cages on a transport, and transporting to the processing facilities. Also, current processes are labor intensive and costly. The problems occur as the DOC (Day Old Chicks) are transitioned from the hatcheries to the growing centers and then to the production facilities. A new system and method for harvesting, loading, growing, transporting, and unloading is needed that addresses the above problems by reducing physical handling of the birds from the hatchery stage through the kill and production stage. In the new system and method, the device by which the birds should be transported should be reusable, interchangeable, and easily cleaned. 
     BRIEF SUMMARY OF INVENTION 
     The technology involves a system and method for handling poultry comprising a colony basket apparatus utilized throughout the process of transitioning the DOC from the hatchery, to the growing facility, through the growing process, and on to the production facility. The colony basket apparatus is utilized for harvesting, loading and unloading, growing, transport, storing and holding through the shackling process prior to the kill process. The method utilizes the colony basket apparatus to perform the steps of retrieving and loading a grouping of the DOC into the colony basket at the hatchery, transporting the same grouping of birds in the same colony basket to the growing facility, loading the colony basket containing the original grouping of birds into the colony system of the growing facility, growing the DOC to Broilers (chickens bred and raised specifically for meat production) in the original colony basket in which they were installed, removing and harvesting live poultry from the colony system while maintaining the same grouping of birds in the same colony basket in which they were originally placed, stacking and loading the colony basket of Broilers on a transport, transporting to a poultry production facility, unloading the colony basket and temporarily storing the poultry in the same colony basket for subsequent killing. The invention more particularly relates to a new portable colony basket for holding and making possible all necessary functions for the poultry animals from the DOC stage, through growing, through transport and up to production while maintaining a grouping of birds or subset thereof in the same colony basket throughout the process all of the way through the shackling process. 
     The concept of harvesting poultry utilizing one type of colony basket uniformly throughout the entire process from capturing the DOC at the hatchery to growing houses equipped with colony systems and on to production will make the process more efficient and will result in less worker and animal stress by resolving many of the problems related to the current methods of manually catching birds and placing in cages or other containers or using semi-automated systems to harvest and transition poultry. With the present invention, stackable tray colony baskets can be utilized that can be placed into and retrieved from colony systems in growing houses using automated systems and can be transferred and retrieved from transports when transitioning between locations within the overall process and the colony baskets can be further integrated with feeding and watering systems. The trays can be made from molded plastic or other material including metal aluminum metal and can have an open grid flexible flooring elevated above a lower manure trap flooring to keep the birds out of their manure and the sides can be vented. The bottoms can have an open grid pattern bottom to allow the birds to grasp with their paws to stabilize and reduce wing flapping, but the floor can also be flexible to reduce injury to the bird. The grid pattern also allows debris and feces to fall out to reduce cleaning and increased airflow to ventilate the birds. The top and bottom perimeter edges of the cages can be complimentary in shape for ease of stacking and stability reducing lateral movement of the stacked trays with respect to each other. The sides of the trays can also have vented openings. Once an upper tray is stacked on top of a lower tray, birds placed in the lower tray are contained. The upper most tray in a stack of trays can be capped by an additional empty tray or other cover or ceiling in the colony system or in the transport or other automated transitioning means. 
     An empty stack of colony baskets can be transported to a hatchery and loaded with DOC. The stack of colony baskets containing DOC can be loaded on a transport rack, which receives the colony baskets and transported to a growing house from the hatchery. The colony baskets can be unloaded from the transport rack to be transferred into a poultry house colony system manually or the transfer can by automated by a powered mover or conveyor and/or loading system. This method provides that no container stacks have to be manually or mechanically un-stacked for loading poultry because the DOC are already in the colony baskets. Previous systems required that trays be removed from a stack and then the poultry would be loaded into the trays and the trays are re-stacked, a powered mover can transport the trays to the outside to be loaded onto the trailer. The process of loading and unloading birds in the growing house has been eliminated. 
     The construction of the trailer can be a flatbed trailer with vertical framework to make up the structural integrity as well as to hold the stacks of individual colony baskets. There can be a plurality of vertical and horizontal rails to insure the structure and flexibility of the size and number of colony baskets the transport is capable of handling. 
     With the design of the present invention, there can be a frame work constructed on the transport trailer holding a lightweight material that can be pulled alongside the trailer to cover the sides. This shroud can create an envelope in which the environment can be better controlled and provide a more suitable environment for the animals. 
     Once the trailer arrives at the plant, the colony baskets can be unloaded and automatically moved into a warehouse or holding facility. This process can be performed as trucks arrive in order to build an entire storage of birds for a production shift. The trucks can be automatically unloaded in a very short period of time, thus eliminating the need for a forklift. The system can work in a “last-in first-out” method. The process can be improved through the efficiency of bringing the birds in the same colony basket that originated at the hatchery and the same colony basket continuing through the growing process and on to the production plant kill area and not consuming time loading and unloading birds into and out of cages or other containers. 
     The automated unloading can be done automatically to pull the trays off the trailer (or flatbed of transport) from the side of the truck in the stacked formation into a transport rack or onto either a conveyor or pull chain system. The transport rack or the conveyor can take the trays to the staging area where they can be un-stacked manually or by using destacker equipment. 
     With the proposed method, the colony baskets provide a perfect transport, growing container and housing means all in one unit to move the birds through the entire process. This system can eliminate the unnecessary handling of the birds and possibly make the process more efficient. 
     In another implementation of the present technology, a modular colony basket (modular tray) is used for the colony basket apparatus. The modular basket can comprise a floor formed of mesh panels and modular side walls that receive a beam extending through a hinge element connecting mesh panels to the floor. As in the previously described colony basket, the modular basket is stackable with other modular baskets and can have all of the functionality and interfaces as the non-modular implementation. The modularity of the basket allows the basket or tray to be periodically disassembled for routine scheduled cleaning and sanitizing, which would be easier than trying to clean and sanitize the whole basket. Further, if only a small section of a basket/tray is damaged, the modularity provided with this implementation allows a given section to be replaced without disposing of the entire tray. 
     There are a number of advantages to the design of the present invention for harvesting poultry. Safety is increased for the handler and the birds and health risks are reduced. The efficiencies of handling and transporting birds is improved and the process is less labor intensive and causes less stress on animals. 
     Moreover, because the present invention teaches the use of a modular colony basket, a method is provided wherein the devices used to transport the birds may be easily disassembled and cleaned before being reassembled. 
     These and other advantageous features of the present invention will be in part apparent and in part pointed out herein below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the present invention, reference may be made to the accompanying drawings in which: 
         FIG. 1  is a colony basket integrated with a watering and feeding system; 
         FIG. 2A  is a perspective view illustration of stacked colony baskets; 
         FIG. 2B  is a side view illustration of stacked colony baskets; 
         FIG. 2C  is an end view illustration of stacked colony baskets; 
         FIG. 3A  is an illustration of a colony basket rack; 
         FIG. 3B  is an illustration of a sectional detail of a colony basket rack; 
         FIG. 4A  is a colony basket rack; 
         FIG. 4B  is a side plan view of a colony basket; 
         FIG. 4C  is a side plan view of a colony basket; 
         FIG. 4D  is a colony basket rack support; 
         FIG. 4E  is a colony basket rack conveyor assembly; 
         FIG. 5A  is a colony basket rack support; 
         FIG. 5B  is a colony basket rack conveyor assembly; 
         FIG. 6  is a flow diagram of the colony basket methodology; 
         FIG. 7  is an illustration of the hatchery conveyor, DOC counter and egg shell separator; 
         FIG. 8  is an illustration of a colony system; 
         FIG. 9  is an illustration of loading colony baskets from a rack to a colony system; 
         FIG. 10  is an illustration of the colony system operation; 
         FIG. 11  is an illustration of a transport loading system; 
         FIGS. 12A, 12B and 12C  are an illustration of loading a transport; 
         FIGS. 13, 14, 15, 16, 17, 18 and 19  are an illustration of transferring colony basket stacks from a colony system to a trailer; 
         FIGS. 20, 21 and 22  are an illustration of retrieving colony basket stacks from a trailer; 
         FIGS. 23 and 24  are an illustration of transferring colony baskets to a kill line; 
         FIGS. 25 and 26  are an illustration of colony baskets traveling through the kill line and the cleaning station. 
         FIG. 27  is a perspective view of an assembled modular poultry raising basket according to the teachings of the present invention; 
         FIG. 28  is a top view of the poultry raising basket of  FIG. 27 ; 
         FIG. 29  is a side view of the poultry raising basket of  FIG. 27 ; 
         FIG. 30A  is a perspective view of a floor panel for the basket of  FIG. 27 ; 
         FIG. 30B  is an alternative perspective view of the floor panel of  FIG. 30A ; 
         FIG. 30C  is a bottom perspective view of the floor panel of  FIGS. 30A and 30B . 
         FIG. 30D  is a front view of the floor panel of  FIGS. 30A, 30B, and 30C . 
         FIG. 31  is a detailed view of a corner of the floor panel of  FIGS. 30A and 30B ; 
         FIG. 32  is an exploded perspective view of assembling four floor panels using a beam for the basket of  FIG. 27 ; 
         FIG. 33  is a detailed view of the intersection of the four floor panels of  FIG. 32 ; 
         FIG. 34  is a cross-section view of an intersection between two adjacent floor panels using a beam for the basket of  FIG. 27 ; 
         FIG. 35  is an illustration of a front lower corner of the basket of  FIG. 27 ; 
         FIG. 36  is an illustration of the side walls of the basket of  FIG. 27 ; 
         FIGS. 37A, 37B, 37C, 37D, 37E and 37F  are various illustrations of a first side panel suitable for forming a side of the basket of  FIG. 27 ; 
         FIGS. 38A, 38B, 38C, 38D, 38E and 38F  illustrate an embodiment of a second side panel configured to mate with the first side panel; 
         FIG. 39  illustrates the stacking of two side panels according to an illustrative embodiment of the invention; 
         FIG. 40  is an illustration of the inside of two stacked side panels; 
         FIG. 41  is an enlarged illustration of region A of  FIG. 40 ; 
         FIG. 42  is an illustration of the outside of the stacked side panels of  FIG. 40 ; 
         FIG. 43  is an enlarged illustration of region B of  FIG. 42 ; 
         FIG. 44  illustrates a stack of modular baskets according to an embodiment of the invention; and 
         FIG. 45  illustrates a frame for a poultry colony employing modular baskets according to an embodiment of the invention. 
     
    
    
     While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF INVENTION 
     According to the embodiment(s) of the present invention, various views are illustrated in  FIGS. 1-45  and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the invention for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the invention should correspond to the Fig. number in which the item or part is first identified. 
     One embodiment of the technology is a single colony basket design adapted to be used throughout poultry processing from the hatchery, through growing and to production. The colony basket includes components designed for the growing process and components designed for transport. The colony basket is adapted for an automated loading system including a stackable tray design, a transport system, and unloading and storing system. 
     The details of the invention and various embodiments can be better understood by referring to the figures of the drawing. 
     Referring to  FIG. 1 , a colony basket integrated with a watering and feeding system is shown. The colony basket growing assembly  100  is shown with a colony basket  102  having vented vertically upright side walls  104  and  106  extending between a top rim flange and a bottom rim flange. The vertically upright side walls include vented areas  108 . The top rim flange includes a plurality of stand-offs as represented by items  110  and  111 . The stand-offs can provide spacing between colony baskets when they are stacked one on top of the other. The bottom rim flange can include complimentary recessed receptacles to receive the stand-offs therein in order to interlock the stacked colony baskets and in order to prevent or resist lateral and longitudinal movement. The top rim flange and the adjacent side wall can have vertical slots  116  and  118  for receiving the water channel and water trough assembly  120  and  122 . The colony basket  102  can also be integrated with a feed channel  124  and feed trough  126 . The feed assembly and the watering assembly can be more generally referred to as sustenance assemblies that can be elevated above the basket for basket removal and installation and ultimately lowered into the basket. The parametrical top rim flange defines an upward facing opening through which birds can be inserted into the basket. The downward facing opening is closed by a floor  112  providing support and a trap for debris. The floor  112  can have placed thereon elongated elevator strips  114  over which a flexible mesh flooring (Not Shown) can be supported and installed. The flexible mesh flooring, not shown, can have small openings through which debris can fall downward through the mesh flooring and be trapped by the floor  112 . The flexibility of the mesh flooring prevents injury to birds standing thereon. The colony basket growing assembly  100  is shown in its configuration when it is integrated within a colony system whereby the birds are housed within the colony basket and provided nourishment for the growing process. For another embodiment, the floor  112  can be a mesh floor and the strips  114  can support the mesh floor. A further modification to this embodiment can include an under panel or cover that removably attaches immediately underneath the mesh floor  112 . 
     Referring to  FIG. 2 , a colony basket stack is shown. In  FIGS. 2A-2C  various views of a colony basket stack  200  is shown. The colony baskets are shown stacked one on top of the other. The colony basket stack  200  can be transported in this configuration and as seen in the various views, the colony baskets are vertically spaced one with respect to the other by the stand-offs  111  and  110 . The bottom facing rim of the basket above can be configured with a mating receptacle recess for receiving the stand-off of the basket immediately below. 
     Referring to  FIG. 3 , a colony basket rack is shown. A rack assembly  300  is shown and configured for a colony system. The rack transfer and conveyor assembly  302  is shown which is utilized to support the colony basket as well as transfer the colony basket into and out of the colony racks of the colony system. The colony system configuration is shown with a feed assembly  304  and a watering assembly  306 . The slot  116  shown where the water assembly  306  can be lowered therein. The feed assembly  304  and the water assembly  306  is shown in a lowered position but can be elevated above the colony basket using a wench system adapted to raise and lower the assemblies so that the basket can be inserted and removed from the colony basket rack without being obstructed by the assemblies. Other drawer designs are not adapted such that watering and feeding assemblies can be raised above or lowered into the container. 
     Referring to  FIGS. 4A through 4E , a colony basket rack is shown, a side plan view of a colony basket is shown, a side plan view of a colony basket is shown, a colony basket rack support is shown and a colony basket rack conveyor assembly is shown.  FIGS. 4A-4E  show the various components of the rack assembly  300  within the colony system configuration. The colony baskets are longitudinally installed within the rack assembly  300 . The longitudinal installation aligns the vertical slots of the colony baskets to be aligned with the water trough system. The components of the transfer system including the support transfer rack  400  and the rack transfer conveyor assembly  302  is also shown. 
     Referring to  FIGS. 5A-5B , a colony basket rack support is shown and a colony basket rack conveyor assembly is shown.  FIGS. 5A and 5B  show further detail of the support transfer rack  400  and the rack transfer conveyor assembly  302 . The rack transfer conveyor assembly  302  includes a conveyor belt  500  and a conveyor roll assembly  502 . The rack transfer conveyor assembly  302  also includes a hydraulic cylinder extension arm  504  that can be utilized to engage the baskets with engagement members  506  and extend to transfer a colony basket stack from one rack to another and/or from one rack to a transport system. The basket cylinder arm and basket retention bar  504  can be actuated to longitudinally extend and retract during retrieval and insertion of a basket. The basket retention bar  504  can include basket engagement members member that engages the basket by applying lateral pressure against the side of the basket and/or engages a complimentary receptor configured to receive the engagement member. The retention bar and engagement member can be rotated about pivot  508  in order to rotate upward to engage a basket or to rotate outward and downward away from the basket. The support transfer rack  400  can support a basket and the support transfer rack can be integral with a rack allowing the transfer rack  400  to elevate or lower the basket with the rack when it is supporting a basket. 
     Referring to  FIG. 6  a flow diagram of the colony basket methodology is shown.  FIG. 6  shows a flow diagram of a circular process utilizing a system of colony baskets throughout the entirety of the process. A given colony basket will retain the same colony (grouping) of birds throughout the process. Initially a colony basket is filled with DOC at a hatchery as reflected by step  600 . Groupings of colony baskets each containing their own individual grouping of birds are then transferred to a growing house (colony farm)  602  where the baskets are loaded into a colony system as reflected by  604 . The birds are retained in the same colony basket in which they were originally installed throughout the growing process and the growing process proceeds as reflected by  606 . The colony baskets are integrated with the watering and feeding systems within the colony system of the growing house. Once the growing process has been completed, the birds are retained in their original colony basket and the baskets are removed from the colony system and transferred to the trailer of a transport as reflected by step  608 . The transport carries the grouping of baskets to a processing plant where the colony baskets are stacked and stored for future processing as reflected by steps  610  and  612 . Again, each of the grouping of birds are retained in their original colony basket throughout the process. The baskets are unloaded as reflected by step  614  and transferred to the kill line as reflected by step  616  or  617  which may be a controlled atmosphere stunning system (CAS) path and there can be separate paths that can be chosen. The birds can be removed from the original baskets in which they were placed and installed on shackles for further processing. The baskets can then be sent through a cleaning process as reflected by step  618 . The cleaned baskets can then be transported to a hatchery  620  and a new batch of DOC can be installed into the baskets and the process can repeat itself. 
     Referring to  FIG. 7 , an illustration of the hatchery conveyor is shown.  FIG. 7  is an illustration of a hatchery system where groupings of DOC  700  can be placed on a conveyor system  702  and transferred into colony baskets by a transfer system  704  and the baskets filled with DOC can then be stacked and transferred to a growing house containing a colony system. The transfer system  704  installs the DOC in a basket and separates the DOC from the shells that remain after the bird hatches. 
     Referring to  FIG. 8 , an illustration of a colony system is shown.  FIG. 8  is an illustration of a colony system where rows of rack assemblies  800  are aligned side-by-side in which colony systems are installed as reflected by Items  800  and  802  respectively. A rack assembly  300  can be utilized for transferring the colony baskets from the rack to the colony system. The colony baskets can be longitudinally installed within the colony system for the growing process. The colony basket stacks  200  can be installed on wheeled platforms for transporting the colony baskets stacks as reflected in the illustration. 
     Referring to  FIG. 9 , an illustration of loading colony baskets from a rack to a colony system is shown.  FIG. 9  is a further illustration of transferring a colony basket stack  900  on a wheeled platform  902  to a colony rack  302  for insertion of the colony baskets into the colony system as reflected by Items  800  and  802 . 
     Referring to  FIG. 10 , an illustration of the colony system operation is shown.  FIG. 10  is an illustration of the growing process in operation whereby workers  1002  utilizing platforms  1004  can tend to the growing process by maintaining the watering and feeding systems. The water and feed assemblies are shown in an elevated position above the basket. When the assemblies are elevated, the baskets can be readily inserted and removed. 
     Referring to  FIG. 11 , an illustration a transport loading system is shown.  FIG. 11  is an illustration of transferring colony baskets  102  from a colony system into a rack assembly  300  for transfer into the transport  1104  having a flatbed  1106 . The colony baskets  102  can be transferred by a transfer conveyor  1102  into a rack assembly  300 . The rack assembly  300  can then be utilized to load the transport  1104  by placing the colony basket stacks on the flatbed of the transport. 
     Referring to  FIG. 12A-12C , an illustration of loading a transport is shown.  FIGS. 12A-12C  is a further illustration of transferring colony baskets from the colony system onto a rack assembly for placement on a flatbed of a transport. 
     Referring to  FIG. 13-19 , an illustration of transferring colony basket stacks from a colony system to a trailer is shown.  FIGS. 13-19  provide an illustration of a step-by-step process for transferring colony baskets from the colony system onto the flatbed of a transport. As illustrated, the basket supports  400  are rotated to receive the first colony basket from level 4. The basket is loaded onto the basket support and a netting material can be installed or draped over the top of the colony basket  102  to retain the birds therein.  FIG. 14  illustrates loading a second basket from level 4 and again applying a netting or other covering material over the top of the basket.  FIG. 15  illustrates loading a third basket from level 3 and again applying the netting material and draping over the top of the basket. This process is repeated for each of the levels of the colony system as two baskets are loaded from each level and then stacked with the previously loaded baskets. 
       FIG. 16  reflects loading the eighth and final basket from level 1 onto the rack transfer conveyor assembly for subsequent stacking of the colony baskets. When a complete stack has been loaded, the basket supports can be rotated outward such that the rack transfer conveyor assembly can begin transferring stacks onto the transport.  FIG. 17  illustrates the completed stack and ready for rotating the basket supports outward to ready the loading of the basket stacks onto the transport.  FIG. 18  illustrates the rack transfer conveyor assembly conveying the basket stacks onto the flatbed of the transport.  FIG. 19  illustrates the completion of the stack loading utilizing the hydraulic cylinder extension arm  1902  for placing and loading the stack onto the flatbed of the transport. 
     Referring to  FIGS. 20-22 , an illustration of retrieving colony basket stacks from a trailer is shown, which is essentially the reverse of the process for loading a trailer.  FIG. 20  is an illustration of subsequently retrieving the basket stacks from the trailer using the hydraulic cylinder arm to engage and pull the stack onto the rack assembly. The hydraulic cylinder arm pulls the stack onto the rack and onto the conveyor for subsequently engaging the support transfer racks for installing and longitudinally inserting the basket into the colony system.  FIG. 21  illustrates the beginning of the process for transferring the basket stacks into the colony system. The transfer support racks can be rotated to engage the colony baskets to begin the process of transferring the baskets into the colony system. A reversal of the previous process can be performed by installing two colony baskets per level, beginning with level 1 and moving upward to level 2, 3 and 4.  FIG. 22  is an illustration of this process. 
     Referring to  FIGS. 23-24 , illustrations of transferring colony baskets to a kill line are shown.  FIG. 23  is an illustration of transferring the colony baskets from the transport to the rack assembly  300  and then transferring the colony baskets onto the colony basket entry conveyor  2302  to convey the colony baskets to the rendering station  2304 . Once the birds have been unloaded from each colony basket, the empty colony basket can then be transferred to the colony basket exit conveyor  2306 . The colony baskets can then proceed through and along the colony basket wash conveyor  2308  which carries the colony baskets through the colony basket washer  2312 . The colony baskets once they are washed can then be reconfigured in a colony basket stack  2310  where the process can be started again. 
       FIG. 24  is an illustration of a colony basket entry station  2402  which is another embodiment for transferring the colony basket stacks from the transport to the rendering station. 
     Referring to  FIGS. 25-26 , an illustration of colony baskets traveling through the kill line and the cleaning station is shown.  FIG. 25  is a further illustration of the rendering or kill line whereby workers remove the birds from the colony baskets and hang the birds on the hanging conveyor shackles  2502 . 
     The process can begin at the hatchery where a grouping of birds (for example DOC) are gathered and placed into a colony basket. A plurality of baskets can be stacked on over top of another for transport. A netting material can be shrouded over each colony basket to assist in containing the birds. The grouping of birds and their respective colony basket in which they are placed can remain in the same colony basket throughout the process until they are removed as broilers at the kill station. This reduces the handling of the birds to avoid injury and helps to prevent the spread of bacteria or disease between bird groupings. The grouping of DOC can be transported to a growing house in the same colony basket in which they were originally placed at the hatchery, where the poultry are grown for future processing. At the growing location there can be a series of growing colony racks for housing the colony baskets with the original grouping of birds placed therein at the hatchery. At the growing facility, the colony baskets can be integrated with water and feed channels and watering and feed troughs. The colony baskets can have a specific configuration to integrate with the watering and feeding systems as outlined herein in order to assist poultry going through the growth process and assist the operators at the growing facility for attending to the birds. When the poultry have completed the growth process, now in the broiler stage, they can be transported to a location for processing as a final food product. A transport can arrive at the growing location to receive the poultry that have completed the growth process. The transport system can be a truck and trailer combination. The trailer can be a standard flatbed trailer on which colony baskets containing the fully grown poultry can be loaded. The colony baskets containing the original grouping of birds, or some subset thereof, can be transferred from the colony racks of the colony system to the flatbed of the transport. A netting material can be shrouded over each basket before it is stacked in order to assist in retaining the bird. The colony baskets can be stacked one atop another. The transport can be loaded with the fully grown birds and transported along a travel route to an unloading station at a processing facility. The transfer system for transferring the colony baskets from the colony racks to the flatbed can be automated as described herein. 
     The unloading station can include an automated unloading system for automatically unloading a colony basket stack from the trailer for storage in an adjacent storage area of the processing facility. Tray stacks can be conveyed to a storage location having a climate controlled storage facility for housing the poultry in the stacked configuration prior to the rendering process. The storage area can be operated on a first in first out system such that a given colony basket stack does not dwell in the storage area for an extended period of time. The storage area can also have a system for controlling and tracking the weight of the tray stacks which could ultimately provide weight information regarding the fully grown poultry. 
     Within the storage facility there can be an automated unstacking system for unstacking the colony basket stacks for conveyance through the processing facility. There can be a stunning system utilized including a gaseous environment for stunning the poultry or it can include an electric shock stunning system or a combination of the two. If a gaseous environment stunning system is utilized, the gaseous environment can be a multi-stage stunning system where the first stage(s) can be a combined induction phase and the second stage(s) can be the combined stunning phase. This system can generally be referred to as a controlled atmosphere stunning system or CAS. Once the colony baskets containing the original grouping of birds/poultry have transitioned through the stunning system, the poultry can be unloaded from the trays at an unloading station. The unloading station can comprise an automated unloading system which is operable to tilt the colony baskets sufficiently to remove the stunned poultry from the colony baskets. This is the first point in the process that the birds are removed since their original placement into the colony basket at the hatchery as DOC. Once removed from the colony baskets, the stunned poultry can be conveyed to a shackling station where the poultry can be hung from a shackle conveyor for being conveyed to a plant evisceration facility. 
     As described the colony baskets can be stackable. Further the colony basket can have an interwoven wire mesh elevated floor above the colony basket bottom floor where the mesh openings are sufficiently large for debris to pass therethrough and also providing a means for the bird to grasp hold in order to stabilize itself and the mesh floor can be flexible in order to avoid injury to the birds. The frame of the colony baskets include various portions including perimeter top and bottom rim flanges and upright vented side walls. The upward facing surface portion of the upper perimeter top rim flange can be designed to be complimentary with respect to the downward facing portion of the bottom perimeter rim flange. This complimentary configuration can be designed such that the trays interlock when they are stacked thereby resisting longitudinal and latitudinal movement of the trays with respect to each other. 
     The stackable tray can be constructed having a top rim flange and a bottom rim flange, which defines the longitudinal and latitudinal dimensions of the tray. The top and bottom rim flanges can have L-shaped cross sections. The inner perimeter of the top rim flange can define an upper opening or upward facing opening through which birds can be easily inserted. The bottom rim flange defines the perimeter of the lower or downward facing opening closed off by the solid floor. The solid floor can have elevators for elevating the mesh floor proximately above the solid floor. The mesh flooring is designed with vented openings where the openings are sufficiently large to allow debris to pass there through. The flexible mesh floor design provides for a surface that can be grasped by the talons of a bird without injury. Upright side walls can be attached around the perimeter of the tray and attached to support members. The inner perimeters of the top rim flange and the bottom rim flange, which define the upper and lower openings respectively, can have substantially the same geometry. 
     The top rim flange can include stabilization standoffs which can extend vertically. The top rim flange can have on an upper surface a vertical standoff. The flange and the complementing recessed receptacle on the underside of the colony basket when engaged, one with respect to the other in a stackable fashion, they can resist longitudinal and latitudinal shifting of trays, one with respect to the other. Also, the stabilization standoffs can be placed along the latitudinal and longitudinal sides of the top rim flange. The spacing between the longitudinal, the latitudinal, and the corner upright support ribs define the vented openings of the tray. The spacing between the support members and the height of the support members can be optimized depending on the type of bird being contained within the stackable trays. 
     For stacked colony baskets the uppermost colony basket can have a top cover or a netting installed of the uppermost colony basket. The top cover can have a mesh screen for covering the opening of the uppermost tray. The perimeter of the mesh screen can be defined by the top cover flange. The top cover flange can have recessed receptacles for interfacing with the raised standoffs of the uppermost tray. 
     The colony basket stacks can be transitioned to the transport and loaded on the flatbed by way of a transfer rack or loading dock or other means for loading the colony basket stacks. Vertically protruding standoffs can be provided on the flatbed for and dimensioned to be received by the recessed receptacles of the lower most colony basket in a stack. The transport can have a shroud covering for better controlling the environmental exposure of the poultry. The shroud covering can be supported by transport side rails. One or both of the side panels of the shroud covering can be a retractable curtain for exposing the flatbed from either side. The shroud covering can also have a rear transport cover opening and or a side transport cover opening through which colony baskets can be loaded. 
     The stacked colony baskets can be loaded through the transport cover opening by sliding them along tray tracks which extend along the flatbed. The trailer can be a standard trailer; however, the trailer can have side railings for supporting shroud covering. The top surface of the flatbed can have raised standoffs that conform to the recessed receptacles on the underside of the tray to restrict lateral sliding or movement of the bottom most tray. 
     The technology described above includes an additional embodiment. In the additional embodiment, the colony baskets described herein above are replaced with modular baskets. The modular baskets may be utilized and integrated interchangeably with the invention described above. 
       FIGS. 27, 28 and 29  illustrate an implementation of a modular basket  2710  suitable for raising poultry or other animals and-or for transporting a product. The illustrative basket  2710  is a modular plastic basket formed of a plurality of interlocking plastic panels. The panels can be formed by injection molding, though other suitable materials and processes may be used to form the panels. In one embodiment, the panels are made of polypropylene and are connected using stainless steel beams. The modular basket  2710  is interchangeable with colony baskets  102  in the invention described herein above and can be fully integrated with other colony baskets in the overall system including integrating with the watering and feeding systems. 
     Each basket  2710  comprises a floor formed by an array of interconnected molded plastic floor panels  2720 . The floor comprises a plurality of corner panels, edge panels and middle panels. Each floor panel can be formed as a flexible mesh panel for allowing animal waste and other debris to drop through while providing a comfortable surface for poultry. In the illustrative embodiment, each floor panels  2720  are identical and formed from the same mold, though the invention is not so limited. 
     Interconnected side panels  2750  are connected to the floor panels  2720  to form side walls for the basket  2710 . As described below, the side panels receive beams that connect the floor panels to each other to connect the side panels to the floor. The side panels have pliable mesh of expanding size. As also described below, the basket  2710  comprises side panels having at least two different, but similar configurations. 
     The basket  2710  has an open top, though the invention is not so limited, and when the sides are assembled, recesses  2751  can be formed to receive watering and feeding systems. 
     The basket  2710  is stackable with one or more other baskets to form a vertical, space-saving stack of apartments. Multiple stacks may be arranged within a frame, or arranged side-by-side to form a colony. 
     The basket as illustrated comprises twenty-five floor panels  2720  and fourteen side panels  2750 , though one skilled in the art will recognize that any suitable number and arrangement of panels may be used to form a basket of any suitable size, shape and configuration. 
     In one embodiment, each floor panel can be between about approximately fifteen and about approximately twenty inches, and one implementation can be between about eighteen and about nineteen inches, by between about approximately twelve and about approximately fifteen inches, and in one implementation can be between about approximately thirteen and about approximately fourteen inches. The side panels have a height between about approximately eight and about approximately twelve inches, and one implementation can be about ten inches and a length between about approximately twenty inches and about approximately twenty five inches. 
     The basket  2710  as illustrated and described may hold about ten lbs per square foot. The number of birds each basket holds depends on the intended slaughter weight of the bird. In one implementation, the basket  2710  may hold about 90 six pound birds, about 140 four pound birds or about 209 2.2 pound birds. 
       FIGS. 30A, 30B, 30C, and 30D  illustrate a single floor panel  2720  suitable for forming a floor, or a portion of a floor, of a modular basket  2710 .  FIG. 31  is a detailed view of a corner of the floor panel  2720 . Each floor panel comprises a flexible mesh floor  3022  extending between edges  3024 ,  3025 ,  3026  and  3027 . A front support beam  3028  extends below edge  3024  and a rear support beam  3029  extends below edge  3025 . The strands forming the mesh  3022  preferably have rounded tops to facilitate run off. In one implementation, the strands have a circular cross-section that is between about 0.100″ and about 0.140′ in diameter. The illustrative strands form square openings  3123  that are between about 0.375″ and about 0.615″ across, though the invention is not limited to the illustrative size and shape. The flexible mesh floor preferably has a certain flexibility to promote comfort and cleanliness. In one embodiment, the flexible mesh floor deflects about 0.5 inches at size pounds of weight in the center. The flexible floor may be more comfortable for the animals. In addition, the flexing may contribute to dried manure cracking off without requiring additional cleaning. 
     The edges slope downwards to create a bowl channeling debris through the mesh openings  3023 . As shown in  FIGS. 30A, 30B, and 31 , the corners of each floor panel  2720  form downward sloping ramps  3041  for channeling debris through the mesh openings. The illustrative ramps  3041  are triangular in shape and widen from the top to the bottom. 
     The center of the floor panel  2720  may be solid for injection molding purposes. 
     The floor panels  2720  include hinge elements  3032 ,  3033 ,  3034 ,  3035  extending below the mesh floor  3022  from each end of edges  3026  and  3027 . A first pair of hinge elements  3032 ,  3033  extends down from edge  3026 , and a second pair of hinge elements  3034 ,  3035  extends down from edge  3027 . The second pair of hinge elements is offset from the first pair. As shown, hinge  3033  is positioned at a corner of the generally rectangular floor panel, whereas hinge  3032  is offset from the corner of the floor panel thereby allowing hinge  3034  of an interfacing abutting floor panel to be position adjacent hinge  3032  and aligned such that beam  3280  may be inserted through the hinge openings. Similarly, on the opposing side of the floor panel, hinge  3034  is positioned at the corner of the floor panel and hinge  3035  is positioned such that it is offset from the corner of the floor panel. Therefore, hinges  3033  and  3034  at diagonally opposing corners of the floor panel are positioned at the corner and hinges  3032  and  3035  are offset from the corner.  FIGS. 32 and 33  illustrate the connection of a plurality of the floor panels  2720  using a beam  3280 . As shown in  FIGS. 32 and 33 , the hinges  3032 ,  3033 ,  3034  and  3035  receive a beam  3280  for linking the floor panels together. The illustrative hinge elements include sloped upper surfaces  3036 , flat sides and flat bottoms, though the invention is not so limited. Each hinge element includes a hinge opening  3039  for receiving the beam  3280 . The illustrative hinge openings  3039  are bone shaped to ease beam insertion and facilitate manufacturability. The illustrative beam  3280  has a rectangular cross-section, but the invention is not so limited. 
     As shown in  FIGS. 32 and 33 , a beam  3280  may be used to join two columns of floor panels to form a floor of a basket, such as the basket  2710  of  FIG. 27 . The illustrative basket  2710  of  FIG. 27  has five columns of floor panels  2720  in five rows, connected using six beams  3280 , though the basket may comprise any suitable number of floor panels in any suitable arrangement. In addition, the floor may comprise multiple beams  3280  per column.  FIGS. 32 and 33  show four floor panels  2720   a ,  2720   b ,  2720   c ,  2720   d  joined together by aligning the hinge elements  3034  and  3035  of the left floor panels  2720   a ,  2720   b  with the hinge elements  3032 ,  3033  of the right floor panels  2720   c ,  2720   d  and inserting a beam  3280  through the aligned hinge elements. 
     As clearly illustrated in  FIG. 30C , the front hinge elements  3032  and  3034  of each floor panel are offset from each other, so that the hinge element  3032  of a right floor panel  2720   c  or  2720   d  is adjacent to and behind the hinge element  3034  of a left floor panel  2720   a  or  272   b  when the floor panels are joined. The hinge element  3032  is spaced from the front edge  3024  of the floor panel by a distance that is equal to or greater than the width of the hinge element  3034  along the length of edge  3026 , so that the corresponding hinge element  3034  fits between the front of the floor panel and the hinge element  3032 . The rear hinge elements  3033 ,  3035  are also offset from each other to allow alignment of the hinges when the edges of the floor panels are brought together. The hinge elements of mating floor panels may abut each other or be spaced apart when joined. The floor panels may have more or fewer hinge elements that interlace. 
     As shown in  FIGS. 30A-34 , each of the edges  3024 ,  3025 ,  3026  and  3027  includes lips  3044  that protrude from the edges. The lip  3044  in one implementation extend along a portion of an edge and is offset to one end of the edge. The lip  3044  is offset to one end of  3025 , whereas the lip  3044  is offset to an opposing end of edge  3024 . Edges  3024 ,  3025 ,  3026  and  3027  also slope downwards to promote debris channeling through the mesh  3022 . Edges  3026  and  3027  are complementary, and edges  3024  and  3025  are complementary, so that the lips of one edge, such as edge  3027 , fit in recesses between lips of a mating edge, such as edge  3026 , as shown in  FIG. 30 . The shaped edges ensure that there is no seam over the beam  3280  to promote cleanliness. The overlapping edges ensure that the seams between the adjoined floor panels remain covered even as the weight of the animals increases and flexes the floor panels. In addition, the edges  3024 ,  3025 ,  3026  and  3027  extend inwards past the beam  3280  by a selected amount to promote the channeling of debris through the mesh  3022  and prevent soiling of the beam  3280 . Thus, the outside edges of the floor  3022  are solid to protect the beam  3280 . For example, in the embodiment shown in  FIG. 34  the distance D between the front of the beam  8320  and the interface between the edge  3027  and mesh  3022  is at least 0.25″ and preferably at least 0.5″. Lip  3044  extends over edge  3026  as illustrated in  FIG. 34  so that the seam is sealed. 
     The side panels  2750  connect to the floor using the beams  3280 .  FIG. 35  is a detailed view of area  3  of  FIG. 29 , showing the connection between a beam  3280  and a side panel  2750  forming a side wall of the basket  2710 . The beam  3280  that passes through and joins adjacent columns of floor panels passes into an opening  3552  in the side panel. The opening  3552  includes recesses to allow twisting of the beam end to lock the beam into place. In the illustrative embodiment, each beam  3280  linking two columns of floor panels passes into an opening in a side panel, but not all side panels receive beams. The edge beams  3280  extend through the hinges of the floor panels along each opposing end forming the short side of the basket floor and the edge beam also extends through the hooks  3769  of each side panel extending along the short side of the basket and these edge beams  3280  extend into the opening  3552  of a side panel  2750   b  extending along a long side of a basket and adjacent a corner. 
     The side panels  2750  are connected together to form the side walls of the basket  2710 . In the illustrative embodiment, each side panel includes links along the first side and second side edges for connecting the side panel to an adjacent side panel. The links are configured such that the side panels may be connected at either 90° or 180°, as shown in  FIG. 36  to form a corner of a side wall. Items  2750   a  and  2750   b  can be configured at a 90 degree angle to form a corner portion of the side wall. 
     The illustrative basket comprises four different configurations of side panels, each with similar features, as described below. 
       FIGS. 37A-37F  are various views of a first side panel  2750   a  suitable for forming a side of a modular basket. The illustrative side panels  2750   a  are used adjacent to diagonally opposite corners on the short side of the basket  2710  of  FIG. 27 . Each side panel comprises a mesh wall formed between upper, lower and side edges. Each side panel  2750  includes female links  3762  on a first side and male links  3772  on an opposite side. The female links each comprise a protrusion  3763  extending from the side edge. The protrusion forming the female link includes two intersecting recesses  3764 ,  3765 . The recesses  3764  and  3765  are perpendicular and have a square-shaped cross-section. The male links  3772  comprise protrusions  3773  aligned with spaces  3766  between the female protrusions. Rods  3775  extend between the protrusions. The illustrative rods  3775  have a square cross-section, with a thicker upper portion and a thinner lower portion. The female links  3762  receive the male links  3772  at either a 90° or 180° to connect two side panels together. As shown in  FIG. 36 , a u-shaped pin  3679  may be inserted into a space between the female protrusions  3763  and male protrusions  3773  to hold the links in place. 
     The side panels  2750   a  further include hooks  3769  extending from the bottom edge for receiving edge beams  3280  that connect floor panels together. 
     The side panels  2750   a  further include a cavity, illustrated as recess  3781 , formed in the top edge for allowing the passage of feeding tubes or pipes. As illustrated, these side panels  2750   a  can be positioned to extend along the short side wall of the basket adjacent the corner of the basket. 
     An inside ledge  3791  extends between the links  3762 ,  3772  above the beam openings  3552 . The ledge  3791  slopes downwards and overlaps the floor panels  2720  when the basket is assembled to promote cleanliness. Even when the floor panels bow under the weight of animals in the basket, the overlap between the inside ledges  3791  and floor panel edges prevent separation between the components. 
     Above the ledge  3791 , the space between the edges of the panels forms an expanding mesh  3793 . The openings  3795  in the mesh  3793  grow larger the higher they are to accommodate growing poultry. In one implementation, the openings are between about approximately one and about approximately three inches wide, where in one implementation the openings are about approximately 2.2 inches and between about one and about approximately two inches tall, preferably about approximately 1.5 inches tall. 
     The side panel  2750   a  further includes openings  3797  below the ledge  3791  to promote airflow. The side panels used in the opposite corners from the side panels  2750   a  are substantially similar, except for the length of the inside ledge  3791 . 
       FIGS. 38A-38F  illustrate an embodiment of a second side panel  2750   b  configured to mate with the first side panel  2750   a . A second side panel  2750   b  is disposed between two first side panels  2750   a  on the short side of the basket  2710  of  FIG. 27 , and a series (four, in the illustrative embodiment) of second side panels are connected at 180° angles along the long side of the basket  2710 . The second side panel  2750   b  includes the same female and male links, mesh, ledge, hooks and openings and further includes a stacking tip  3851  extending upwards from the top edge. The bottom edge includes a recess  3861  for receiving the stacking tip of a side panel in a basket below. For the long side of the basket, the second side panel  2750   b  has a minimal inside ledge  3791 . 
       FIGS. 39-43  further illustrate the means by which side panels  2750   b  of baskets  2710  stacked on top of one another engage one another. As illustrated, stacking tip  3851  includes a pyramid-shaped protrusion  3852  having a flat front face  4153  and two straight protrusions  3854 ,  3855  opposing the pyramid-shaped protrusion for gripping the bottom edge of an overhead panel. When stacked, the stacking tip allows for a space  4070  to be formed between the overhead and below baskets. 
       FIG. 44  illustrates a stack  4400  of nine modular baskets  2710 . Multiple baskets may be stacked together for transportation as described in the previous embodiment. The baskets are self-stacking and stabilized on top of each other. 
       FIG. 45  illustrates a frame  4500  for a chicken colony employing modular baskets. The frame includes multiple levels, each level housing a row or more of modular baskets. A conveyor belt may be used to convey the modular baskets  2710  on and off of the frame as described in the previous embodiment. 
     The illustrative modular plastic basket provides a comfortable, sanitary, accessible environment with optimal air flow and ventilation for raising chickens or other products. The modular plastic baskets are easily assembled and stackable to save space. 
     Poultry can be raised in the basket from the beginning to the end of life. The basket may be easily removed from a poultry house and trucked to a process facility, where it is unloaded, cleaned, then sent back to a hatchery or poultry house. 
     The various poultry handling examples shown above illustrate a novel system and method for handling poultry. A user of the present invention may choose any of the above chicken handling embodiments, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject chicken handling could be utilized without departing from the spirit and scope of the present invention. 
     As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope of the present invention. 
     Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.