Patent Description:
Conventional animal processing methods utilize controlled atmospheric stunning to irreversibly stun an animal prior to additional processing the animal for ultimate consumption. Various gases and mixtures of gases are used during the stunning process. Animals are transported into a single structure containing the gases in a gradient of concentration for a period of time allowing the animal to succumb to the effects of the gases and reach a state of irreversible stunning, thereby allowing the animal to be processed by hand or machine. Document <CIT> and document <CIT> A1describe such a method and a corresponding apparatus.

Disadvantageously, the conventional processing methods stress the animals, and result in unwanted injury or damage to the animals. Further, conventional processing methods require a particular arrangement of apparatuses and structures that have undesirable costs and features, and lack flexible application and implementation. Previously there has not been available a controlled atmospheric stunning apparatus, system, and method with the advantages and features of he disclosed subject matter.

In the controlled atmospheric stunning methods and apparatuses according to the invention, animals pass through a first environment with a first stunning gas to achieve unconsciousness followed by optionally a second environment with a second stunning gas to achieve irreversible unconsciousness. Segregating the stunning process into two phases decreases the distance of vertical travel through the gases required to render the animals unconscious and irreversibly unconscious, and increases control of the process thereby minimizing unwanted stress of the animals and minimizing damage to the animals. Further, the distance the animals travel through the first phase is less than the distance of travel in the sole structure used in conventional methods allowing the first and second phases to be above ground, partially above ground, or completely below ground, thereby reducing construction and operating costs, and allowing greater adaptability to existing facilities.

The drawings constitute a part of this specification and include exemplary embodiments of the disclosed subject matter and illustrate various objects and features thereof.

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.

Certain terminology will be used in the following description, and are shown in the drawings, and will not be limiting. For example, up, down, front, back, right and left refer to the disclosed subject matter as orientated in the view being referred to. The words, "inwardly" and "outwardly" refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forward, rearward, upward, and downward are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

Referring to <FIG>, a controlled atmospheric stunning system <NUM> for stunning an animal prior to slaughter is shown and described whereby the animals travel through a first environment, and optionally a second environment. Animals are gathered at their place of origin and transported to a processing facility where the animals are stunned prior to slaughter.

Referring to <FIG>, animals <NUM>, such as poultry, are placed in crates <NUM> assembled into modules <NUM> at the place of origin, such as a farm, for transportation to the processing facility. The crates <NUM> have sidewalls and a bottom wall for containing the animals <NUM> with openings to allow airflow. For example, a first upwardly open crate 154a is placed at the bottom of a frame <NUM> allowing a worker to gather and place an animal <NUM> into the first crate 154a, and fill the crate 154a with a number of animals <NUM>. Once the first crate 154a is filled, it is pushed into the frame <NUM> and a second crate 154b is placed within the frame <NUM> above the first crate 154a. The second crate 154b forms the roof of the first crate 154a and is loaded in the same manner as the first crate 154a. The third crate 154c is placed above the second crate 154b and loaded in the same manner as crates 154a and 154b. The process is repeated until all of the crates <NUM> of the module <NUM> are filled. Thereafter, one or more modules <NUM> filled with animals <NUM> in crates <NUM> are arranged on a truck for transport to reception <NUM> at the processing facility. From reception <NUM> the animals <NUM> may proceed directly to module unloading <NUM>, or first proceed to lairage <NUM> for a period of time. Lairage <NUM> allows the animals <NUM> to calm and become comfortable with the new environment after being transported from the place of origin. The animals <NUM> move from lairage <NUM> to module unloading <NUM>. From module unloading <NUM> the animals <NUM> move to stunning <NUM>. From stunning <NUM> the animals move to slaughtering <NUM>.

The general stages of an embodiment of an exemplary processing facility are shown in <FIG> and are described below.

Animal <NUM> processing begins with module unloading <NUM> whereby the crates <NUM>, and unnumbered crates of animals <NUM> are placed on a conveyor <NUM>, such as an endless conveyor, and the conscious animals <NUM> are advanced into the first environment <NUM>. In an embodiment, stunning <NUM> consists of a first phase <NUM> having a first environment <NUM>. The first environment <NUM> consists of an enclosure <NUM> for containing gases. The enclosure <NUM> has an inlet <NUM> allowing the crates <NUM> to enter the enclosure <NUM> and first travel vertically within the enclosure <NUM> on a descending run <NUM> of the conveyor <NUM>. The crates <NUM> next move laterally within the enclosure <NUM> on a lateral run <NUM>, and exit the enclosure <NUM> at an outlet <NUM> after traveling vertically on an ascending run <NUM> of the conveyor <NUM>. In an implementation, the system <NUM> has a conveyor <NUM> with a single descending run <NUM>, single lateral run <NUM>, and single ascending run <NUM>. In an implementation, the system <NUM> has conveyors <NUM> with two or more descending runs <NUM> as shown in <FIG>, <FIG>, and <FIG>. In another implementation, the system <NUM> has conveyors <NUM> with two or more side-by-side conveyors <NUM>, each having two descending runs <NUM>, thereby having a total of four descending runs <NUM>, two lateral runs <NUM>, and two ascending runs <NUM>. In an implementation, the system <NUM> has a plurality of conveyors <NUM>.

Referring to <FIG>, the first environment <NUM> forms a first airspace <NUM>, defined by the enclosure <NUM>, extending between a top <NUM> area and a bottom <NUM> area, the airspace <NUM> forming an upper zone <NUM> above a lower zone <NUM>. The conveyor <NUM>, moving in the direction of arrow <NUM>, moves each crate <NUM>, including the unnumbered crates, into the first environment <NUM> with the animals <NUM> first moving into the upper zone <NUM>. The descending run <NUM> of the conveyor <NUM>, moving in direction of arrow <NUM>, moves the animals <NUM> from the top <NUM> area to the bottom <NUM> area through the first environment <NUM> from the upper zone <NUM> to the lower zone <NUM>.

A first gas is supplied within the first airspace <NUM>. In an embodiment, the first gas is carbon dioxide in combination with ambient air. In an embodiment, the gases supplied within the first airspace <NUM> along with the first gas includes a mixture of gases. For example, in an implementation, the gas is a mixture of carbon dioxide, ambient air, and oxygen gas. In an implementation, the carbon dioxide concentration is about <NUM>%. Exposing the animals <NUM> to a carbon dioxide concentration of <NUM>% for one minute is enough to stun the animals <NUM>. A <NUM>% carbon dioxide concentration is necessary to render most animals <NUM> (including poultry) unconscious. In an implementation, the carbon dioxide concentration is about <NUM>% and the oxygen concentration is between about <NUM>% and about <NUM>%. The addition of oxygen gas to the carbon dioxide and ambient air mixture decreases the gasping response of the animals <NUM> due to the high concentration of carbon dioxide. In the exemplary implementation, the oxygen gas can be replaced with nitrous oxide gas, argon gas, helium gas, or ozone gas. Alternatively, in an implementation, the sole gas is helium gas, nitrous oxide gas, or argon gas.

Movement of the conveyor <NUM> and crates <NUM> through the first airspace <NUM> causes a mixing of the gases within the first airspace <NUM> resulting in a general gradient of gases forming within the first airspace <NUM>. For example, carbon dioxide is heavier than ambient air, and carbon dioxide tends to form a vertical gradient within the first airspace <NUM> upon mixing of the carbon dioxide. In an implementation, the carbon dioxide in the first environment <NUM> ranges in concentration from about <NUM>% at the top <NUM> area to about <NUM>% at the bottom <NUM> area (<FIG>). In an implementation, the carbon dioxide concentration at the bottom <NUM> area is at least <NUM>%. In an implementation, the carbon dioxide concentration at the bottom <NUM> area is between about <NUM>% to <NUM>%. It is known in the art that passing an animal through a gradient of carbon dioxide gas that increases in concentration to about <NUM>% within about <NUM> to <NUM> minutes in order to render the animals unconscious avoids adverse reactions or trauma to the animals. The first environment <NUM> is monitored by one or more sensors <NUM> located within the first enclosure <NUM> for measuring environmental conditions, such as gas sensors for measuring the presence and concentration of gases, temperature sensors, and humidity sensors. The sensors <NUM> are spaced throughout the first airspace <NUM> to measure environmental conditions at locations within the vertical gradient. The condition of the animals <NUM> as they travel through the first environment <NUM> is monitored by one or more imaging devices, such as a camera <NUM>, spaced throughout the gradient. The sensors <NUM> and cameras <NUM> are operably connected to a programmable logic computer adapted to control movement and speed of the conveyor <NUM> through the environment, the speed of the descending runs <NUM>, lateral runs <NUM>, and ascending runs <NUM> of the conveyor, and the volume and concentration of gasses in the environment.

Upon reaching the bottom <NUM> area, the animals <NUM> have resided within the first environment <NUM> between about <NUM> minutes to about <NUM> minutes, preferably about <NUM> minutes to about <NUM> minutes, and are rendered unconscious. The slow and gradual movement of the crates <NUM> from the upper zone <NUM> to the lower zone <NUM> minimizes unwanted stress on the animals <NUM>, such as convulsions and gasping, and unwanted injuries from jumping or flopping, such as wing damage, bleeding of the tissues or joints, or blood spots. The crates <NUM> then move along a lateral run <NUM> of the conveyor <NUM>, moving in direction of arrow <NUM>, from beneath the descending run <NUM> to beneath the ascending run <NUM>. The crates <NUM> ascend from the bottom <NUM> area to the top <NUM> area along the ascending run <NUM> of the conveyor <NUM> moving in direction of arrow <NUM>, and exit the first environment <NUM> through the outlet <NUM>. In an implementation, the movement of each crate <NUM> along the descending run <NUM>, and in turn the movement of the animals <NUM>, through the first airspace <NUM> is at a first speed, and the movement of the crate <NUM> and animals <NUM> along the ascending run <NUM> is at a second speed. In an embodiment, the second speed is greater than the first speed. In an implementation, the ascending run <NUM> travels twice as fast as the descending run <NUM>. In an implementation, the first speed results in a travel time of the animal <NUM> along the descending run <NUM> within the first airspace <NUM> of between about <NUM> minutes to about <NUM> minutes.

In an embodiment, each crate <NUM> moves from the first phase <NUM> or first environment <NUM> immediately to slaughtering <NUM>. An advantage of the first and second environment controlled atmospheric stunning system <NUM> is the ability to optionally move the unconscious animals <NUM> immediately to slaughtering <NUM> after traveling through the first environment <NUM> thereby allowing alternative processing methods to take place, such as halal processing <NUM>. In another embodiment, the animals <NUM> move from the first phase <NUM> or first environment <NUM> immediately to a second phase <NUM> or second environment <NUM> to be rendered irrevocable unconscious prior to slaughter <NUM> (<FIG>).

Referring to <FIG>, the second environment <NUM> consists of an enclosure <NUM> for containing gases for an optional second phase <NUM> of the stunning <NUM> operation. The second environment <NUM> includes sensors <NUM> and cameras <NUM> operably connected to a programmable logic computer for controlling the conveyor <NUM> and gases similar to the first environment <NUM>. The enclosure <NUM> has an inlet <NUM> allowing the crates <NUM> to enter the enclosure <NUM> on a descending run <NUM> of the conveyor <NUM>, moving laterally within the enclosure <NUM> on a lateral run <NUM>, and exiting the enclosure <NUM> after an ascending run <NUM> of the conveyor <NUM> at an outlet <NUM>. The second environment <NUM> forms a second airspace <NUM> extending between a top <NUM> area and a bottom <NUM> area, the airspace <NUM> forming an upper zone <NUM> above a lower zone <NUM>.

The conveyor <NUM>, moving in the direction of arrow <NUM>, moves each crate <NUM>, including the unnumbered crates, from the first environment <NUM> into the second environment <NUM> with the unconscious animals <NUM> first moving into the upper zone <NUM> of the second environment <NUM>. The descending run <NUM> of the conveyor <NUM>, moving in direction of arrow <NUM>, moves the animals <NUM> from the top <NUM> area to a bottom <NUM> area through the second environment <NUM> from the upper zone <NUM> to the lower zone <NUM>. The speed of the conveyor <NUM> during the descending run <NUM>, lateral run <NUM>, and ascending run <NUM>, determines the dwell time of the animals <NUM> within the first and second environments <NUM>, <NUM>.

A second gas is supplied within the second airspace <NUM>. As with the first airspace <NUM>, a combination of gases may be used in the second airspace <NUM> forming gradients of concentration due to movement of the conveyor <NUM> and crates <NUM> through the second airspace <NUM>, and such gases and combinations of gases are incorporated herein. In an embodiment, the second gas is carbon dioxide and forms a concentration within the lower zone <NUM> of about <NUM>% (<FIG>). In an implementation, the carbon dioxide concentration at the bottom <NUM> area is between about <NUM>% up to <NUM>%. Exposing the animals <NUM> to a concentration of carbon dioxide gas of about <NUM>% concentration or greater, for a period of time will render the animals <NUM> irrevocably unconscious. In an implementation, the sole gas is helium gas. Similar to the first environment <NUM>, the second environment <NUM> includes one or more gas sensors <NUM> for monitoring the environmental conditions, such as gas presence and concentration, within the second environment <NUM>, and one or more imaging devices, such as cameras <NUM> for monitoring the condition of the animals <NUM>. Upon reaching the bottom <NUM> area, the animals <NUM> have resided within the second environment <NUM> for between about <NUM> to <NUM> minutes and are rendered irrevocably unconscious upon reaching the bottom <NUM> area. The crates <NUM> then move along a lateral run <NUM> of the conveyor <NUM>, in the direction of arrow <NUM>, from beneath the descending runs <NUM> to beneath the ascending run <NUM>. The crates <NUM> ascend from the bottom <NUM> area to the top <NUM> area along the ascending run <NUM> in the direction of arrow <NUM>, and exit the second environment <NUM> through an outlet <NUM>. In an implementation, the movement of each crate <NUM> along the descending run <NUM>, and in turn the movement of the animals <NUM>, through the second airspace <NUM> is at a first speed, and the movement of the crate <NUM> and animals <NUM> along the ascending run <NUM> is at a second speed. In an embodiment, the second speed is greater than the first speed. In an implementation, the ascending run <NUM> travels twice as fast as the descending run <NUM>. In an implementation, the first speed results in a travel time of the animal <NUM> within the second airspace <NUM> of between about <NUM> minutes and <NUM> minutes. Upon exiting the second environment <NUM>, the animals <NUM> move to slaughtering <NUM>.

Processing animals <NUM> first through the first environment <NUM> followed by the second environment <NUM> results in this animals <NUM> traveling the descending run <NUM> of the second environment <NUM> at a faster rate than they travel along the descending run <NUM> of the first environment <NUM>. Stated alternatively, the animals <NUM> reside or dwell in the first environment <NUM> for a greater amount of time than in the second environment <NUM>.

In an embodiment, the environments <NUM>, <NUM> are entirely below the floor <NUM> of the facility, whereby the enclosures <NUM>, <NUM>, and <NUM> are surrounded by the ground <NUM>, forming open-top pits, constructed entirely of reinforced concrete (<FIG>). In an embodiment, the environments <NUM>, <NUM> are partially below the floor <NUM> of the facility, whereby the enclosures <NUM>, <NUM>, and <NUM> are constructed partially or entirely of reinforced concrete (<FIG>). In an embodiment, the environments <NUM>, <NUM> are entirely above ground <NUM> and the enclosures <NUM>, <NUM>, and <NUM> are constructed of reinforced concrete (<FIG>). In an implementation, the enclosures <NUM>, <NUM>, and <NUM> include thermal insulation to allow temperature control of the environments <NUM>, <NUM>. In an implementation, in each of enclosures <NUM>, <NUM>, and <NUM> the distance between the top and bottom is about ten feet. In another embodiment, the vertical distance between the top and bottom of enclosure <NUM> is less than the distance between the top and bottom of enclosure <NUM>, such as the vertical distance in the second enclosure <NUM> is about five feet, and the vertical distance in the first enclosure <NUM> is about ten feet. In some implementations, the enclosures <NUM>, <NUM>, and <NUM> are sealed to prevent gases from escaping into the atmosphere. Accordingly, the inlets <NUM>, <NUM>, and <NUM>, and outlets <NUM>, <NUM>, and <NUM> are constructed to allow the crates <NUM> and conveyor <NUM> to pass through, such as by a moveable sealed door.

Referring to <FIG>, in an embodiment, the first environment <NUM> and second environment <NUM> are within a single enclosure <NUM>, and the environments <NUM>, <NUM> are formed or partially separated by a divider <NUM> and separator. The conveyor <NUM>, moving in the direction of arrow <NUM>, moves each crate <NUM>, including the unnumbered crates, into the first environment <NUM> within the enclosure <NUM> through an inlet <NUM>. The descending runs <NUM> of the conveyor <NUM>, moving in direction of arrow <NUM>, transits the first environment <NUM> from the top <NUM> area to the bottom <NUM> area through the upper zone <NUM> and the lower zone <NUM> of the first airspace <NUM>. The first environment <NUM> is supplied with a gas, and the gas forms a vertical gradient in concentration due to a mixing of the gas by movement of the crates <NUM>, etc. as described above.

In an implementation, the carbon dioxide in the first environment <NUM> ranges in concentration from about <NUM>% at the top <NUM> area to about <NUM>% at the bottom <NUM> area (<FIG>). In an implementation, the carbon dioxide concentration at the bottom <NUM> area is at least <NUM>%. In an implementation, the carbon dioxide concentration at the bottom <NUM> area is between about <NUM>% to <NUM>%. It is known in the art that passing an animal through a gradient of carbon dioxide gas that increases in concentration to about <NUM>% within about <NUM> to <NUM> minutes in order to render the animals unconscious avoids adverse reactions or trauma to the animals. Upon reaching the bottom <NUM> area, the animals <NUM> have resided within the first environment <NUM> between about <NUM> minutes to about <NUM> minutes, preferably about <NUM> minutes to about <NUM> minutes, and are rendered unconscious.

The crates <NUM> then move on a lateral run <NUM> of the conveyor <NUM>, in the direction of arrow <NUM>, from the lower zone <NUM> beneath the descending runs <NUM> to the lower zone <NUM> beneath the ascending run <NUM>, passing from the first environment <NUM> to the second environment <NUM> beneath the divider <NUM>. In an embodiment, a separator depends from the divider <NUM>, such as a water screen <NUM>, separates the first environment <NUM> bottom <NUM> area from the second environment <NUM> bottom area thereby keeping the gases within the environments <NUM>, <NUM> separated. In an embodiment, the water screen <NUM> includes antimicrobial agents, such as ozonated water, cleaning the animals <NUM> and treating any active microbial processes.

Within the second environment <NUM> a second airspace <NUM> extends between a top <NUM> area and a bottom <NUM> area forming an upper zone <NUM> above the lower zone <NUM>. The gases within this second environment <NUM> are the gases and combination of gases described above with respect to the second environment <NUM>.

In an embodiment, the second gas is carbon dioxide and forms a concentration within the lower zone <NUM> of about <NUM>% (<FIG>). In an implementation, the carbon dioxide concentration at the bottom <NUM> area is between about <NUM>% up to <NUM>%. In an implementation, the sole gas is helium gas. Upon reaching the bottom <NUM> area, the animals <NUM> have resided within the second environment <NUM> for between about <NUM> to <NUM> minutes and are rendered irrevocably unconscious upon reaching the bottom <NUM> area.

The crates <NUM> move from the bottom <NUM> to the top <NUM> along the ascending run <NUM> in the direction of arrow <NUM> and exit the second environment <NUM> through an outlet <NUM> onward to slaughtering <NUM>. The first and second environments <NUM>, <NUM> include cameras <NUM> and sensors <NUM> as described above. In an implementation, the movement of each crate <NUM> along the descending run <NUM>, and in turn the movement of the animals <NUM>, through the first airspace <NUM> is at a first speed, and the movement of the crate <NUM> and animals <NUM> along the ascending run <NUM> through the second airspace <NUM> is at a second speed. In an embodiment, the second speed is greater than the first speed. In an implementation, the first speed results in a travel time of the animal <NUM> within the first airspace <NUM> of between about <NUM> minutes to about <NUM> minutes, and the second speed results in a travel time of the animal <NUM> within the second airspace <NUM> of between about <NUM> minutes to about <NUM> minutes.

After slaughtering <NUM>, the animals <NUM> move on to subsequent stages of processing, including chilling <NUM>, processing <NUM>, packaging <NUM>, storage <NUM>, and shipping <NUM>. Processing <NUM> may include cut-up, deboning, and grading.

The bi-phasal continuous flow system described above with regard to the controlled atmospheric stunning system <NUM> results in gas stunning of the animals <NUM> with minimal carbon dioxide consumption by the animal <NUM>. In addition, the controlled rate of descent of the animals <NUM> within the first environment <NUM> reduces animal <NUM> damage and improves the quality of the harvested tissues.

Claim 1:
A method of gas stunning an animal prior to slaughter, comprising:
providing a first environment extending between a top area and a bottom area, the first environment including a first airspace extending between the top area and the bottom area;
supplying the first airspace with a first gas, wherein the first gas increases in concentration within the first airspace moving from the top area to the bottom area;
providing a second environment extending between a top area and a bottom area, the second environment including a second airspace extending between the top area and the bottom area;
supplying the second airspace with a second gas, wherein the second gas has a concentration within the second airspace bottom area between about <NUM>% and up to <NUM>%; and
advancing an animal through the first environment from the top area to the bottom area where the animal is rendered unconscious, followed by advancing the animal through the second environment from the top area to the bottom area rendering the animal irrevocably unconscious, wherein the animal is advanced through the first airspace from the top area to the bottom area at a first speed; and
wherein the animal is advanced through the second airspace from the top area to the bottom area at a second speed, wherein the second speed is greater than the first speed.