Building A Chicken Plucker: Using Old Rims For Efficiency

Chicken plucking is a time-consuming and laborious task, and while there are commercial plucking machines available, they can be expensive. One cost-effective alternative is to build your own chicken plucker at home using rims and other easily accessible materials. This DIY approach has gained popularity among those who raise chickens for sustenance or those living off the grid, as it saves time and ensures efficiency when processing poultry for meals. With various plans and instructions available online, even those with limited DIY experience can create their own chicken plucker to simplify the chicken plucking process.

Sourcing the materials

The first thing to consider is the base of your plucker. Many DIY chicken pluckers use a 55-gallon food-grade plastic barrel, which is durable, easy to clean, and safe for poultry processing. You can often find these barrels recycled or second-hand, which can significantly reduce costs.

Next, you'll need to gather the components for the internal mechanism. The "fingers" of the plucker, which do the actual plucking, are typically made of rubber. These can be purchased new or made from sturdy rubber materials. You'll need around 100 of these fingers, which are often one of the most expensive components.

For the plucker's frame, you can use wood or metal. If using wood, opt for pressure-treated lumber to withstand moisture. Metal components that come into contact with the birds should ideally be made of stainless steel.

You'll also need a motor to power the plucker. A 3/4 or 1 horsepower motor is commonly used and can be sourced second-hand, such as from an old grain mill.

Other electrical components include a switch, GFCI outlet, and wiring. You may also want to add automatic water capabilities with PEX tubing and a valve.

Finally, you'll need various hardware such as washers, screws, and a driveshaft. Don't forget to also budget for any additional tools you may need during the build, such as a drill.

With careful sourcing and a bit of creativity, you can build an effective chicken plucker without breaking the bank.

Building the drum

The first step is to choose the right drum for your chicken plucker. The most popular option is a 55-gallon food-grade plastic barrel, which can be purchased new or repurposed from recycled materials. This material is durable, easy to clean, and safe for poultry processing. It is important to note that you should not cut the entire top off the drum, but rather leave a rim of about 1/2" to 1" to maintain its structural integrity and prevent bending or warping.

The next step is to create the "fingers" that will line the inside of the drum. These can be purchased or made from sturdy rubber materials. Mark out the positions for the rubber fingers and use a drill to create holes for the screws. Prepare large washers by drilling clearance holes for the screws and a centre hole to accommodate the drive shaft. Attach the rubber fingers to the washers and then to the drive shaft.

Some people choose to add a feather plate or bottom plate, which spins inside the drum. This can be made from metal or wood and is where the rubber fingers are attached. If you choose to include a feather plate, ensure that it is securely attached to the drive shaft and that all holes are drilled and reamed to accommodate the feathers.

Finally, consider adding wheels to your drum for mobility and a sturdy base to prevent movement during operation. You may also want to paint the drum to waterproof it and protect it from the elements. Regular maintenance and cleaning of your drum and its components are crucial to ensure smooth operation and the longevity of your chicken plucker.

Adding the rubber fingers

To add the fingers, you'll need to first mark out their positions. Use a 30mm wood drill to drill holes to a depth of 12mm or adjust the depth to suit the dimensions of your rubber fingers. Prepare large washers by drilling four clearance holes for the screws. Drill a centre hole to accommodate the drive shaft. You can then attach the rubber fingers to the plate using the washers and screws. Ensure the plate is attached securely to the drive shaft.

The placement of the rubber fingers may vary depending on your design. Some opt to stagger the fingers around the barrel or drum, while others choose to place them in plain rows. You can insert the fingers around the circumference of the drum or barrel, or you may prefer to section the drum and rivet a strip to the inside bottom of the drum to facilitate easier maintenance and cleaning.

The number of rubber fingers you'll need will depend on the size and design of your plucker. Most pluckers require around 100 rubber fingers, but you may need more or less depending on your specific setup.

Motor setup

For example, one source mentions using a 0.37kW (0.5 HP) motor from an old grain mill, which successfully handles plucking two chickens at a time and can manage a run of 50 chickens in a morning. However, articles they referenced suggested a 0.75 or 1 HP motor. Another source mentions a 1 HP electric motor in their setup.

The motor is connected to a power source, typically through a waterproof switch, and it powers the rotation or vibration of the rubber fingers or discs within the drum. This mechanism mimics manual plucking but at a much faster rate.

It is important to regularly inspect the motor and electrical components for any signs of wear or damage. Frayed wires or worn-out parts should be replaced promptly to maintain the safety and efficiency of the machine.

Cleaning and maintenance

To build a chicken plucker out of rims, you will need a 55-gallon, food-grade plastic barrel, a few 2x4s, rubber 'fingers', and a 3/4 horsepower motor. You will also need a drill, washers, a drive shaft, and a pulley.

To ensure your chicken plucker is always in good working condition, regular cleaning and maintenance are necessary. Here are some detailed instructions for cleaning and maintaining your chicken plucker:

Cleaning the Rubber Fingers

• After each use, remove any remaining feathers from the rubber fingers. Use a soft brush or cloth to wipe down the fingers, ensuring they are free of any debris.
• Once the feathers have been removed, spray the fingers with a disinfectant solution. You can use a mixture of mild soap and warm water, or a specialised poultry disinfectant. Ensure all surfaces of the fingers are coated.
• Rinse the fingers thoroughly with clean water to remove any soap residue.
• Dry the fingers completely before storing the plucker. Leaving the fingers damp can lead to the growth of bacteria or mould.

Cleaning the Barrel

• After each use, remove the barrel from the plucker and rinse it with clean water. Ensure that any feathers, dirt, or debris are washed away.
• If there is a build-up of dirt or grease, use a mild detergent and a soft brush to scrub the barrel gently. Pay particular attention to the areas where the fingers attach to the barrel.
• Rinse the barrel thoroughly with clean water to remove any detergent residue.
• Dry the barrel completely before reassembling the plucker.

Maintaining the Motor and Moving Parts

• Regularly inspect the motor and all moving parts for any signs of wear or damage. This includes the drive shaft, pulley, and any belts or hinges.
• Grease the moving parts as needed to ensure smooth operation and reduce friction. Refer to the motor's user manual for specific recommendations on lubrication.
• If any parts show significant wear or damage, replace them promptly to ensure the safe and efficient operation of the plucker.
• Ensure that the electrical connections are secure and free of debris or corrosion.

General Maintenance

• Before and after each use, inspect the plucker for any signs of damage or wear. This includes checking the stability of the structure and the condition of all components.
• Keep the plucker clean and dry when not in use. Store it in a dry, covered area to protect it from the elements.
• Regularly review and tighten any bolts or fasteners to ensure the plucker remains sturdy and stable during operation.
• If using a water spray system to lubricate and flush away feathers, ensure the hoses and nozzles are clear of any blockages.

By following these cleaning and maintenance instructions, your chicken plucker built from rims will continue to operate effectively and safely.

Frequently asked questions