Jake Harper
Building a tub-style chicken plucker can be a great way to save money and time for those who want to process their own chickens. Commercial tub pluckers can cost upwards of $2000, but with some creativity and craftsmanship, it is possible to build a comparable unit for $500 or less. The basic idea behind a tub plucker is that you flip a switch, drop the birds into the tub, and watch as the machine quickly removes all the feathers. This process can be completed in a matter of seconds, making it a much faster and more efficient method than hand-plucking. While there are various plans and resources available online for building a tub-style chicken plucker, one popular option is the Whizbang plucker, which has been featured in books and online forums. The Whizbang plucker is known for its speed and effectiveness in plucking chickens, and its plans are relatively easy to follow, making it a popular choice for those looking to build their own machine.
| Characteristics | Values |
|---|---|
| Name | Tub-Style Chicken Plucker |
| Other Names | Whizbang Plucker |
| Cost of Commercial Version | $2,000+ |
| Cost of Homemade Version | $450-$700 |
| Time Taken to Build | Varies, but can take a lot of time |
| Number of Birds it can Hold | 1-2 birds at a time |
| Time Taken to Clean a 10lb Bird | 10-15 seconds |
| Ease of Build | Relatively easy to follow plans, but requires craftsmanship |
| Materials Required | Plastic barrel, wooden legs, light switch, light switch box, metal cover, V belt, motor, wiring, rubber fingers, metal connecting hardware, PEX tubing |
| Additional Information | The feather plate is the most challenging part to build |
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What You'll Learn
Sourcing materials
- Feather Plate and Spinner Plate: These two components are the most specialised parts of the machine and may require machining. You could attempt to make these yourself if you have the necessary metalworking skills and equipment, or you could enlist the help of a friend with metalworking expertise, as mentioned in some online accounts.
- Tub: The tub is a crucial component, and a standard 23" OD (outside diameter) plastic barrel is commonly used. This size can accommodate 1-2 birds at a time, with a 10-lb bird taking around 10-15 seconds to clean. You may be able to source a suitable plastic barrel locally or online.
- Motor and Wiring: You can source these from an old washing machine or a fan/blower. This is a cost-effective way to reuse existing appliances.
- Legs: Wooden legs can be constructed from old 2x4s or similar pieces of lumber that you may have on hand or can easily source from a hardware store.
- V Belt: A longer V belt is necessary for the machine's operation, and you can purchase this from automotive or hardware stores, such as Napa.
- Rubber Fingers: These are essential for the plucking action. You can purchase these online or directly from the author of the "Whizbang" plan book, Herrick Kimball.
- Miscellaneous Hardware: Various metal connecting hardware, such as lag bolts, screws, and other fasteners, will be needed. These can be purchased from hardware stores or online.
- Plans and Instructions: If you intend to follow specific plans, such as the popular "Whizbang" design, you can purchase plan books or kits directly from the author or through online retailers. These plans will provide detailed parts lists and instructions.
It is important to note that costs may vary depending on the availability of materials and your willingness to repurpose existing items. Some people have reported building their plucker for around $450 to $700, while others have spent closer to $1200 for a ready-made option.
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Building the feather plate
If you do decide to build the feather plate yourself, you will need to start with a hollow shaft, which you will then need to replace with a solid shaft so it can be keyed. The key is for the 15.5" pulley to hold on to. The feather plate should be pre-drilled for the rubber fingers. You can then drill six more holes (three on either side of the centre) and mount six fingers under the plate so they sweep the bottom of the barrel and keep the feathers swept into the chute.
The feather plate is the main ingredient in building the rest of the plucker. Once you have this component, it is just a matter of scrounging materials to build the rest of the machine around it.
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Constructing the frame
The frame should be made of wood and fitted to a barrel, which will serve as the tub of the plucker. The barrel should be cut to the appropriate size and shape to fit snugly within the wooden frame. It is recommended to use a standard 23" OD plastic barrel, which can hold 1-2 birds at a time.
After assembling the frame, you need to consider the bearings. Mount one bearing at the top and one at the bottom of a 4x4 and drill a larger hole through for the shaft. This will ensure the smooth rotation of the barrel within the frame.
The next step is to create a drain or exit for the feathers and water. This can be done by cutting a small slot in the edge of the barrel and attaching an angled chute made of sheet metal. A 5-gallon plastic bucket with a hole drilled for water drainage can be placed at the end of the chute to catch the feathers.
Overall, constructing the frame of a tub-style chicken plucker involves fitting a wooden frame to a barrel, adding bearings for rotation, and creating a drainage system for feathers and water. With careful craftsmanship and the right materials, you can create a functional and efficient plucker.
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Adding the motor and wiring
Once you have the motor, you will need to attach it to the plucker using a V-belt. The V-belt connects the motor to the shaft of the feather plate, allowing the motor to rotate the feather plate. The length of the V-belt will depend on the specific design of your plucker, but it should be long enough to allow for a smooth rotation without slipping.
The wiring for the motor will depend on the specific type of motor you are using. If you are using a motor from an old washing machine, you may be able to reuse the existing wiring. Otherwise, you will need to purchase electrical wiring that is suitable for your motor. The wiring will need to be connected to a power source, such as a battery or a power outlet. It is important to consult an electrician or a professional if you are unsure about the wiring process to ensure safety.
In addition to the motor wiring, you will also need to install a light switch and a light switch box. These components will allow you to turn the plucker on and off easily. The light switch box should be mounted in a convenient location, and the wiring should be connected to the power source. Again, it is important to ensure that all electrical connections are made by a qualified professional to avoid any safety hazards.
Finally, you may want to consider adding some additional wiring for safety measures. For example, you could install a kill switch that allows you to quickly turn off the plucker in case of an emergency. This kill switch could be wired in parallel with the light switch, so that either switch can cut power to the motor. This provides an additional layer of safety for the operator.
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Testing and adjustments
Testing the Machinery:
Before using your tub-style chicken plucker on actual chickens, it is essential to conduct a dry run to ensure all components are functioning correctly. Test the machine's mechanics by turning it on and observing the rubber fingers' movement. Ensure they are rotating smoothly and vigorously enough to pluck feathers effectively. Check for any unusual noises or vibrations that could indicate a problem with the motor or assembly.
Adjusting Feather-Plate and Finger Spacing:
The spacing of the feather plate and fingers is critical for optimal plucking. Adjust the spacing between the fingers to ensure they are close enough to effectively pluck the feathers. You may need to stagger the fingers for more comprehensive coverage. The feather plate should be securely mounted, with additional fingers added underneath if necessary to sweep the barrel's bottom and keep feathers and water directed toward the exit chute.
Testing Water Flow and Drainage:
If your design includes a water flow system to wash away feathers, test the water flow rate and ensure it effectively removes feathers without causing excess water to build up in the tub. Adjust the water flow and check the drainage system to prevent flooding or blockages.
Testing on Actual Chickens:
When you're satisfied with the machine's performance, it's time to test it on actual chickens. Start with one or two scalded birds, following the procedure outlined in the user manual. Observe the plucking process carefully, ensuring the machine does not damage the bird's skin or bruise the meat. Adjust the timing as needed to strike a balance between thorough plucking and efficiency.
Fine-Tuning and Optimisation:
After the initial tests, make any necessary adjustments to optimise performance. This may include fine-tuning the finger spacing, adjusting the water flow, or tightening any loose components. Test the machine on a larger batch of chickens to ensure it consistently performs as expected.
Remember to refer to the Whizbang plucker plan book or similar resources for detailed instructions and troubleshooting guidance specific to your plucker's design.
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Frequently asked questions
A tub-style chicken plucker is a machine that automates the process of plucking feathers off chickens. It is called a "tub-style" plucker because it uses a tub where the chicken is placed and the feathers are plucked.
Building a tub-style chicken plucker can save you money in the long run, as commercial tub pluckers can cost upwards of $2,000. Building your own plucker can cost around $450 to $700, depending on the materials used and whether you have some of the parts already available. Additionally, it can save you time and effort compared to hand-plucking feathers.
You can find plans and instructions on how to build a tub-style chicken plucker in books such as "Anyone Can Build a Tub-Style Mechanical Chicken Plucker" by Herrick Kimball, or online forums and websites. The materials required include a feather plate, spinner plate, plastic barrel, motor, wooden legs, and various metal connecting hardware. Some materials may need to be machined or crafted specifically for the plucker, while others can be sourced from old washing machines or other sources.
