A patented ultrasonic carcass treatment system that deep-cleans follicles and surface-decontaminates broiler carcasses in-line — with water recirculation, dual-component treatment, and 24/7 remote monitoring.
Product Overview
Duplex™ is UltraBiotecs' patented ultrasonic system that reduces pathogens in poultry without chemicals. Positioned as the last process before the chiller, it runs on the fastest production lines with full automation — simply start at the beginning of the shift and stop for emptying before cleaning.
The system syncs pump speed with line speed to create a controlled water pocket around each bird, minimising cross-contamination and back-contamination between carcasses on the shackle line.
Water is sterilised by system heat and continuously recirculated, while spray cabinet water is reclaimed — cutting consumption to just 2 m³/hr versus 10+ m³/hr in traditional systems. This dramatically reduces water, energy and operating costs while delivering superior hygiene and food safety performance.
Duplex™ achieves validated pathogen reduction through patented ultrasonic physics alone — no antimicrobial chemicals are applied to the carcass. This eliminates residue concerns, simplifies regulatory compliance, and removes chemical handling risks from the processing environment entirely.
Because Duplex™ uses no chemicals and restores birds to their original temperature after each treatment stage, there is zero impact on colour, texture, odour or shelf life. Treated carcasses are indistinguishable from untreated product in independent organoleptic assessments — your product quality is fully preserved.
How It Works
Duplex™ uses two sequential ultrasonic treatment tanks, each targeting a different aspect of pathogen removal, followed by bespoke spray cabinets to restore carcass temperature — all within the existing line footprint.
Stage 1
In the first process tank, precisely controlled ultrasonic harmonics deep-clean feather follicles, disrupt biofilms and dislodge pathogens. Feather follicles are the primary reservoir for Campylobacter on the dressed carcass — conventional spray systems cannot penetrate them. Duplex™ reaches where other technologies cannot.
Stage 2
In the second tank, a different harmonic set surface-cleans the birds and damages pathogen cell membranes. This membrane disruption does not kill pathogens outright at this stage — instead it primes them for greater reduction during chilling, creating a compounding effect that extends beyond the Duplex™ unit itself.
Stage 3 & 4
After each tank, birds are cooled back to their original temperature in bespoke spray cabinets — ensuring zero organoleptic change to the product. The system also separates physical contaminants without filters, preventing recontamination of subsequent carcasses in the water bath.
Water is sterilised by system heat and continuously recirculated. Spray cabinet water is also reclaimed, cutting consumption to 2 m³/hr versus 10+ m³/hr in traditional cabinet washing systems — a reduction of over 80%.
The system is monitored online 24/7 from our UK control centre. We offer full installation and training free of charge, three service visits per year, and replacement of any failed components — also free of charge.
Validated Performance
All data generated at an ISO/IEC 17025-accredited contract research organisation using EURL-validated quantitative surface methods. Results expressed as log₁₀ CFU/cm² reductions on artificially contaminated broiler neck-skin.
| Target Organism | Inoculum (log₁₀ CFU/cm²) | Post-Treatment Count | Log Reduction | Contact Time | Result |
|---|---|---|---|---|---|
| Campylobacter jejuni NCTC 11168 | — | — | — | — | — |
| Campylobacter coli ATCC 33559 | — | — | — | — | — |
| Salmonella Typhimurium DT104 | — | — | — | — | — |
| Salmonella Enteritidis PT4 | — | — | — | — | — |
| Listeria monocytogenes Scott A | — | — | — | — | — |
| E. coli O157:H7 | — | — | — | — | — |
Data pending. Results will be expressed as log₁₀ CFU/cm² reductions on artificially contaminated broiler neck-skin from an ISO/IEC 17025-accredited CRO.
Line Integration
Duplex™ is installed as a single, self-contained unit positioned as the last process before the chiller — the optimal point for maximum pathogen reduction before the product reaches the cold chain.
Installed after evisceration and the inside-outside bird washer (IOBW), Duplex™ intercepts carcasses after the highest-risk contamination stages and treats them before they enter the chiller.
Position: Last step pre-chill
The system runs fully automatically once started at the beginning of a shift. Pump speed syncs with conveyor line speed in real time — no manual adjustment required, regardless of throughput variations.
Operation: Fully automated
Designed for the fastest commercial production lines. The controlled water pocket mechanism maintains consistent treatment regardless of line speed, ensuring uniform efficacy across every bird.
Compatibility: All throughput rates
Duplex™ is designed for retrofit into existing slaughter-line infrastructure. Full installation and operator training are provided free of charge by UltraBiotecs engineers, minimising downtime and capital risk.
Install: Free of charge
Full laboratory reports, SDS sheets, and a process integration assessment are available to qualified processors and technical buyers.
Contact Our Technical Team