Integrating Worker and Food Safety in Poultry Processing Through Human-Robot Collaboration: A Comprehensive Review

Abstract

This comprehensive review synthesizes current advances and persistent challenges in integrating worker safety and food safety through human-robot collaboration (HRC) in poultry processing. Rapid industry expansion and rising consumer demand for ready-to-eat poultry products have heightened occupational risks and foodborne contamination concerns, necessitating holistic safety strategies. The review examines ergonomic, microbiological, and regulatory risks specific to poultry lines, and maps how state-of-the-art collaborative robots (“cobots”)—including power and force-limiting arms, adaptive soft grippers, machine vision, and biosensor integration—can support safer, more hygienic, and more productive operations. The authors analyze technical scientific literature (2018–2025) and real-world case studies, highlighting how automation (e.g., vision-guided deboning and intelligent sanitation) can reduce repetitive strain injuries, lower contamination rates, and improve production consistency. The review also addresses the psychological and sociocultural dimensions that affect workforce acceptance, as well as economic and regulatory barriers to adoption, particularly in small- and mid-sized plants. Key research gaps include gripper adaptability, validation of food safety outcomes in mixed human-cobot workflows, and the need for deeper workforce retraining and feedback mechanisms. The authors propose a multidisciplinary roadmap: harmonizing ergonomic, safety, and hygiene standards; developing adaptive food-grade robotic end-effectors; fostering explainable AI for process transparency; and advancing workforce education programs. Ultimately, successful HRC deployment in poultry processing will depend on continuous collaboration among industry, researchers, and regulatory authorities to ensure both safety and competitiveness in a rapidly evolving global food system.