How do they make boneless?

Boneless chicken is a popular staple in many diets and recipes. But have you ever wondered how they actually make boneless chicken? The process of removing bones from chicken parts is fascinating, and it allows us to enjoy juicy, tender chicken breasts, thighs, and wings without having to worry about bones. In this article, we’ll explore the step-by-step process of how they make boneless chicken.

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Why Do They Make Boneless Chicken?

There are a few key reasons why boneless chicken is so popular:

Convenience – Boneless chicken parts are easier to eat, cook, and serve. You don’t have to worry about removing bones or choking hazards.
Versatility – Boneless chicken can be used in a wide variety of recipes from soups and salads to sandwiches, wraps, and more. The meat also cooks more evenly without bones.
Cost – Removing the bones allows processors to get more usable meat from each chicken. This brings down costs compared to bone-in parts.

Appeal – Many consumers simply prefer the ease and convenience of boneless chicken over bone-in varieties.

By investing in the process of removing bones, chicken suppliers and brands are able to cater to consumer demand for boneless options.

Where Does Boneless Chicken Come From?

Almost all boneless chicken comes from whole chickens that are processed mechanically by machines in a food manufacturing facility. Here’s an overview of the supply chain:

Whole chickens are delivered to the facility after being processed at a chicken harvesting operation.
The chickens are put on a line to start the boneless processing.
Machines are used to systematically debone each section of the chicken.

Workers may help with trimming and cutting the finished boneless pieces.
The boneless chicken is packaged, labeled, and shipped out for retail sale.

A very small amount of specialty boneless chicken is hand-trimmed by skilled meat cutters. But this is rare as it is much more time-intensive and costly than mechanical deboning processes.

How Do the Machines Debone Chicken?

Specialized chicken deboning machines streamline what was traditionally a very labor-intensive manual process. The machines utilize sharp blades, rollers, and pressurized water jets to systematically separate bone from meat.

Here are some of the main steps in the mechanical deboning process:

Conveyor Line – Whole chickens are loaded onto a conveyor system that allows them to move through the deboning machinery. The line is calibrated to the processing speed of each machine.

Cutting – Circular saw blades make strategic cuts through joints to start separating chicken parts. This releases some bones for easier removal.
Bone Removal – A machine applies pressure and water jets to force bones away from meat. Rollers help push bones through the perforations made by the cutting blades.
Trimming – Workers along the line may hand trim any excess fat, cartilage or small bones missed by the machine.

Packaging – At the end of the line, boneless chicken is weighed, packaged and labeled for retail sale.

Automated deboning systems like this allow for thousands of chickens to be processed hourly. The speed and efficiency maximize boneless chicken output.

Types of Chicken That Get Deboned

Virtually all parts of the chicken can be mechanically deboned including:

Breasts – The breast is split in half and then deboned. Skin is left on for extra flavor and moisture.
Tenders – These are thin tenderloins attached to the underside of breast, easily removed.
Thighs – Deboned thighs maintain their juicy dark meat after bones are removed.

Drumsticks – The bone is taken out while keeping the signature drumstick shape.
Wings – Wing bones are removed and the remaining meat is portioned into drumettes, flats, and tips.

In some cases, whole muscle cuts like tenderloins may be manually deboned first before machines process the rest of the carcass. This ensures prime white meat remains intact.

Are There Different Grades of Boneless Chicken?

There are not official USDA grades for boneless chicken like there are for beef. However, some general attributes indicate quality:

Color – Fresh boneless chicken should be pale pink or white. Avoid gray or yellow discoloration.
Smell – Raw chicken has a mild odor. Rancid or foul odors may signal spoilage.

Texture – Smooth, moist flesh that is not overly slimy or sticky.
Sell-by date – Purchase boneless chicken before its sell-by date for maximum freshness.
Fat trim – Excess fat and cartilage is typically removed but some fat ensures juiciness.

Water content – Higher-quality boneless chicken contains less water and fills out packaging better.

Opting for well-known chicken brands and paying close attention to sensory cues for freshness can help you pick high-quality boneless chicken.

Common Questions About Boneless Chicken

Here are answers to some frequently asked questions about boneless chicken and how it’s made:

Is mechanically separated chicken the same as boneless?

No, the two are produced differently. Mechanically separated chicken uses more intense processing to extract remaining meat and paste from chicken carcasses. True boneless chicken keeps cuts intact.

Does boneless chicken cook differently than bone-in?

Yes, boneless chicken cooks faster since heat can penetrate evenly without bones. Take care not to overcook boneless pieces since they easily dry out without bones keeping moisture in.

Can you make chicken boneless at home?

It is possible to debone chicken at home using a sharp boning knife but takes time and skill. Much easier to simply purchase ready boneless chicken rather than doing it yourself.

Is boneless chicken processed with chemicals?

Reputable brands use only mechanical processes like blades, rollers and water jets for deboning. No chemicals are involved in making premium quality boneless chicken.

Is boneless chicken less healthy than bone-in?

Nutritionally, boneless chicken offers the same protein, nutrients and minerals as bone-in cuts. The only difference is the absence of bones, so health impacts are minimal.

Conclusion

Boneless chicken is simply whole chicken that has been mechanically processed to remove bones for convenience and cost efficiency. By utilizing specialized deboning machines in processing facilities, chicken suppliers can produce premium quality boneless parts like breasts, thighs, and wings quickly and profitably. While the lack of bones may change cooking methods slightly, overall boneless chicken remains tasty, nutritious and easy to use in all your favorite recipes.