IntellIgent batchIngRobobatcheR Flex and I-cut 122

FOcUS On POlanD

cUStOMeR caSeS FROM all OVeR the WORlD

StoRK nuoVa coRetech

poultry processingInsightM

ay

2016 | en

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This year we will be launching a new structure for the Marel brand. This edition of Insight shows you the new look. Step by step all our other communications will receive the new treatment which reflects the very latest design.

our activities will be grouped under the name Marel Poultry instead of Marel Stork Poultry Processing. this doesn’t mean, however, that the Stork Poultry Processing brand will disappear. You will continue to find the name of Stork marked clearly on our equipment; you won't be able to pass by without noticing the Stork Poultry Processing brand on our exhibition booths, websites, advertisements and brochures.

together with the new brand structure, you’ll also see our new tagline “advancing food processing”, because that’s our core business. We want to bring food processing to the next level. We want to keep on improving. that is our passion and that's why Marel Poultry wants to continue to be the leading provider of advanced processing solutions to the global poultry industry.

the year 2015 was for Marel Poultry another record year! this was due to a tailwind in a number of markets. at the same time we are well aware that this could only be accomplished thanks to the support and confidence of our customers. So we definitely won’t change our commitment to support you and assist you in getting the best possible results with our systems and equipment.

We strive to have even better results in 2016. We will, however, have some challenges to conquer, as the world’s economic and political situation can n

influence our business. but we’re well prepared and well equipped to meet most of these challenges.

When a national economy is booming, such as in Poland, we benefit from increasing investments by the agrifood industry in that country. In this edition of Insight you’ll read all about recent developments in Poland, which in a very short time has become europe's largest broiler processing country.

advancing food processing must also be put in the context of topical subjects such as sustainability and food safety. that’s why modern poultry processing requires a focus not just on individual equipment, but even more on advanced process control. We are rolling out innovations such as “fixed weight fillet processing” by integrating the Robobatcher Flex and the I-cut 122. these overarching solutions involve the smart interaction of multiple machines. the same goes for SystemFlex conveyor logistics, connecting processes in an intelligent way. the primary goal of these innovations is to make daily processing easier and more efficient, giving a high return on investment.

I wish you a good read and look forward to meeting you personally at one of our events.

antOn De WeeRD, ManagIng DIRectOR MaRel POUltRy

Insight

New braNd STrucTure, cOMMItMent UnchangeD

poultry processing

New brand structure

Nuova CoreTech evisceration

Nutrypollo

SystemFlex conveyor systems that fit

Charming Food introduces air chilling in Taiwan

“A robot with a knife”

Poland – a MarelPoultry success story

New filletingdepartment at Avisabor

I-cut 122 PortionCutter taking portioning to the next level

CAS SmoothFlow breakthrough in South America

Suprieya Foods moves tosemi-automation

Quality always comes first at Broviand

Twice from grain to chicken

Serving the French polyvalentmarket

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cOntentS

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the Stork nuova coretech technology provides evisceration solutions for all processing capacities up to 6,000 bph (100 bpm), taking into account that giblet harvesting will be done manually. Processors can have immediate access to proven technologies of the sophisticated nuova eviscerating system without having to invest in equipment which meets the highest automation requirements and the highest line speeds. upgrades to the coretech system can easily be incorporated later on, without the need to change the entire platform. as a result, the coretech can “grow along” with the processor.

eaSy UPgRaDe

coretech is the ideal solution for processors starting up who want to begin automating their evisceration process, while continuing to harvest giblets manually. In time, they can decide to upgrade the system by adding a viscera pack shackle line, allowing automated rehanging and giblet harvesting. In this way, increasing levels of automation can be integrated gradually in line with growing capacity or changes in market demands.

PROVen technOlOgy

built on 20 years’ experience, the nuova coretech eviscerator offers all the advanced features today’s processes demand, while providing flexibility for future needs. Function is identical to existing nuova systems, but does not include automatic rehang of the viscera pack. coretech does not have separate viscera shackles, but positions the entire viscera pack over the back of the product.

exact POSItIOnIng

Stork’s nuova coretech eviscerator can cope with various line speeds and large variations in flock size and weight. the products enter the system with their backs towards the center of the carrousel. the eviscerator compensates automatically for differences in size,

by positioning each broiler exactly for a perfect evisceration result, with no adjustment to settings being needed.

MaRketS WIth SPecIFIc neeDS

besides being ideally suited to processors starting up in any market in the world, Stork nuova coretech will also be of interest in specific markets with cultural or religious inspection demands. that’s because the viscera pack which hangs over the back of the product allows for specific veterinary inspection. When establishing the health status of a flock, inspectors find organs such as lungs, heart and liver very important. While still attached to the product, the intestine pack is visibly presented for assessment; product and organs are accessible on all sides for thorough inspection.

this is crucial, as certain religions or cultures require a focus on specific organs. as such, nuova coretech provides products suitable for halal, kosher and super kosher inspection procedures.

the flexibility and versatility of Stork’s nuova coretech eviscerator will help processors just beginning with industrial poultry processing to obtain the best possible evisceration yield in all circumstances.

gO tO: MaRel.cOM/cORetech

nUOVa cORetech eVISceRatIOnServINg STarT-upS aNd SpecIfIc MarkeTS

the eVISceRatIOn PROceDURe

Placed in-line after the vent opening machine, the coretech eviscerator is a carrousel machine with 20 units. Its task is to remove the entire viscera pack, including heart, lungs, liver, gizzard and intestines, from the body cavity in one single, automated operation.to remove the pack, a drawing arm enters the product through the abdominal cavity opening. When the arm is completely inside, it grasps the esophagus, and draws it out together with the scraped-out intestine pack. the consistent and thorough way in which the system works practically eliminates any possible damage to the intestine pack or the product itself.the drawing arm then positions the entire viscera pack over the back of the product, ensuring a high level of hygiene and aiming to prevent contamination.

hygIene

cleaning is done with great care. high pressure cleaning of parts which have been in contact with the product takes place after each operation cycle. the products themselves as well as the viscera packs are cleaned by low-pressure spray nozzles. this hygienic way of working virtually eliminates any risk of contamination. nuova coretech uses considerably less water compared to conventional systems.

“nuoVa coRetech can ‘gRoW along’ WIth the PRoceSSoR.”

processing plants need a lot of flexibility to get the most value out of their operations. The Stork Nuova coreTech system has been developed to bring maximum evisceration efficiency to processors newly starting up or to processors who operate in markets with specific requirements. at a later point in time coreTech can be upgraded to a full scale Nuova system.

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their commitment to quality brought a natural fit to partner with Marel Poultry to build the first demonstration plant showcasing a full Stork Poultry Processing evisceration, killing and selection line in Mexico. the project, which began in 2012, includes an entire Stork nuova evisceration line, with giblet harvesting and handling. additionally, Stork stunning, killing and picking solutions were installed.

cOnFIDence

When the time came for expansion, nutrypollo looked for a solutions provider that they could trust to achieve their plans of reaching capacities of 12,000 bph (200 bpm). “We chose Stork Poultry Processing because the brand is known for its quality,” says general Manager cesar Quesada. “the name gives us confidence.”

See ReSUltS FIRSt

because they trusted the brand, nutrypollo wanted to benefit from the latest in processing technologies at very high line speeds and also be the first to show Stork’s equipment, solutions and performance to important Mexican customers. “We see Marel Poultry as high tech and a leader in the meat processing market but we had to see results at 12,0000 bph,” adds Senor Quesada.

the results are in and everyone is pleased with how the line is running. two years ago, the plant was processing 60,000 birds per day with 20 people operating in evisceration on an eight-hour shift. now, nutrypollo is running 80,000 birds per day, without overtime, and it only takes six hours.

the FaSteR, the betteR

“We had invested lots of time into getting very good results from our old equipment. but we didn’t know how much time we had to invest to get at least the same results with our new equipment.

at first the line ran at 8,400 bph (140 bpm), but later on, we increased the speed, with new automatic harvesting equipment added. to our surprise, the faster we ran the new line the better everything worked, and finally, at full speed, we got the best results,” says Marketing director Patricio Quesada.

SeRVIce aFteR the Sale

equally important to nutryPollo is the partnership after the sale. they wanted to be sure they could maintain the equipment at a high performance level, also at higher line speeds. here again, their trust in Marel Poultry and the mutual relationship were decisive. that’s why the company signed a two-year Premium hardware Service level agreement for their eV equipment, covering parts and labor.

MaIntaInIng tOP qUalIty

“now our processing plant is a reference of quality and innovation in our region

and we are always happy to invite our customers. So they can understand that the high quality of our chicken comes from maintaining top quality in all of the processes, from hatching to distribution, and especially those processes that can really make a difference and can literally be seen and felt in our final product.

We take special pride in our plant because every single customer, supplier or colleague tells us that it’s the best looking and one of the most modern plants they’ve ever seen,” says Patricio Quesada.

gO tO: nUtRyPOllO.cOM

nUtRyPOllO IS “SyNoNyMouS wITh ToTal qualITy”

as a fully integrated company with a processing capacity of 12,000 bph (200 bpm), Nutrypollo has earned its position as one of Mexico’s best-known poultry processing companies through their commitment to “the art of the good breeder”. Nutrypollo, a second generation family business, takes pride that their company is “synonymous with total quality”.

abOUt nUtRyPOllO

From their beginning as an egg laying farm in 1950 by Mr. bernardo Quesada de alba, father of general director Mr. Jorge Quesada Moran, to the start of the broiler business in 1963, to their newest successes running at 12,000 bph (200 bpm), the company has enjoyed more than 50 years in the Mexican market. their commitment to quality and seeking out the newest and highest levels of technology from partners they trust is their strategy.

the success of this large expansion project and the excellent results have positioned nutrypollo well for future plans. they want to expand their product offerings into further processed products, grow their rotisserie sales and increase their scope of supply to include some other regions of Mexico like Jalisco. Marel Poultry is committed to helping nutrypollo to achieve their goals.

FROM leFt tO RIght: on behalf of nutrypollo: alejandro Pineda, Francisco guevara, Patricio Quesada (Plant Manager), Salvador and armando hermosillo. on behalf of Marel Poultry: gerardo Jimenez, edwin de Koning, Koen Serrarens and christjan van haperen.

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Well-designed internal logistics improve product flow, safeguarding quality in the process. a conveyor belt solution in a poultry processing plant must, therefore, address many different requirements: it must be hygienic, reliable, process embedded, flexible and silent, yet at the same time controllable and easily cleanable. the SystemFlex solution has it all.

MODUlaR FlexIbIlIty

by using functional, modular building blocks giving the desired height, width, length and curve, SystemFlex can solve all internal logistic issues. With a minimal number of components, i.e. 48 master building blocks, any desired, tailor-made configuration can be created. So every single processor can build an individually

optimized, unique conveyor system. a SystemFlex conveyor system will always fit like a glove!examples of the building blocks are support frames, bends, inclines (ups), declines (downs), drive and return sections. at the very minimum, the conveyor would consist of a drive end, an idle end and a support frame.

ReUSable cOMPOnentS

besides the master building blocks, the clever coupling method allows for the installation of a wide range of accessory components, such as product scrapers, catch plates, infeed funnels, work surfaces, work stations, product and tray guides, cable trays, belt washing/spraying equipment and belt lifters (for optimal ease of cleaning).

Should layouts change over time, almost all components can be reused, depending of course on the changed requirements. Modules are easy to install, remove and use again. there is no necessity to buy a completely new system and previously used, costly materials aren’t wasted.

keePIng the IntegRIty

Food safety is an overriding concern when conveying products through the plant. besides bringing products safely and hygienically to the next process step, SystemFlex also reduces human contact with the product by automatically positioning products correctly for in-feed into a downstream machine.

SystemFlex conveyor belts contribute to maintaining the integrity of products during their journey through the process. they prevent product quality loss and enhance throughput. In an ideal situation, each product is put down on the belt once only, with no need for tumbling, flipping or any further movements.

ShelF lIFe

the more “bare meat” is tumbled, flipped or otherwise moved around during the process, the more it loses its protein, the more its adhesion force weakens, the shorter its shelf life will be. a well-handled product can reach a shelf life of 12 or 13 days; under less optimal circumstances, shelf life can be reduced to 5 days.

With its strong technological background and experience in the area, Marel Poultry successfully ensures product integrity. even if a proper, careful handling of bare fresh meat adds just one day to shelf life, this is extremely valuable for customers.

hyDROPhObIc

SystemFlex belts are built to prevent soiling; belts stay clean in almost all circumstances. as dry meat products tend to attach themselves to the belt, detaching would always leave remnants, causing the end product to lose weight.

SystemFlex conveyors prevent this by using a hydrophobic coating on the belt material.

eaSIly cleanable

the SystemFlex concept meets the highest standards in safety, ergonomics and hygiene in the food industry. Its components are made from durable materials, resistant to moisture and cleaning agents. In either wet or wash-down environments, safety of products and equipment is ensured. the conveyed products, raw meat or packed, are not at risk, but are always carefully treated.

Product damage, loss or bulking as well as bacterial contamination can be prevented.

gO tO: MaRel.cOM/SySteMFlex

“theY PReVent PRoduct QualItY loSS and enhance thRoughPut.”

SySTeMflex

cOnVeyOR SySteMS that FItfor those who really care about adding value to a processing system, a conveyor belt is not just a simple means of transport for getting product from a to b. Marel poultry developed the Systemflex modular conveyor system to generate an interactive logistics environment and thereby maintain product quality and optimize process integration. The Systemflex integrated solution is very much more than a mere transport belt.

MOtORS anD beltS

the focus on standardization and true quality is also reflected in the choice of motors for SystemFlex conveyors. only three motor types are used; green labeled, efficient and reliable motors with constant torque over a very wide speed range. the conveyor motors can be connected to the central management system, in order to monitor their performance. In this way, it becomes easy to take preventive measures, such as speeding up or slowing down specific conveyors.

depending on the width required and the curves specified for the conveyor, a homogenous or modular belt material can be chosen. all belts are available in different thicknesses and pitch distances, and have the option of a middle lane or flights.

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being a greenfield project, the charming Food plant could start from scratch, adopting the very latest poultry processing techniques and setting new standards for taiwan. “In our search for the best possible way of automating processing on an industrial scale, we concluded that the solutions of the world’s prime brand Marel Poultry met our requirements best”, says chairman Yao Kun hung.

every single detail in the plant meets a state-of-the-art standard, such as climate control, the supply of purified water for washing and the overhead stainless steel work.

MUltIPle FlOORS

In taiwan, where space is very limited, charming Food was the country’s first company in years to build a greenfield project. the plant is located directly behind the company’s own edible oil silos, sitting tightly between other factories in the port city of tai chung, on

the west coast of the island. What’s so special, is that the building is earthquake-proof and features multiple floors! the first floor holds the live supply, killing and evisceration departments, the control room is on the mezzanine level, while cut-up and grading lines are located on the second floor.

tRaceabIlIty anD eaRly gRaDIng

charming Food’s strong focus on traceability starts early in the process with product being graded by an IRIS inspection system installed immediately after defeathering. the earlier each product is assessed, the easier it is to track product accurately down the line, particularly if use is also made of advanced Innova software throughout the process. IRIS grades each product individually, using size, shape, color and texture to assess defects. grading data remains attached to product right through the process up to packaging and labeling, providing full traceability.

Mr. hung continues, “It’s in the interest of the consumers that traceability of food production is guaranteed all the way from the source to the end product to provide consumers with better products.”

aIR chIlllIng

charming Food is taiwan’s first processor to replace the traditional water cooling method with in-line air chilling equipment. With a total length of almost two kilometers (1975 m, 6480 ft) the Stork downFlow Plus chilling tunnel, with its accurate temperature management, is able to chill product rapidly using cold air. the moisturizing cabinets, part of Stork’s “Plus” technology moisten product surfaces to prevent dehydration and control the presentation and color desired. “to us, being the first processing plant to use air cooling equipment in taiwan, it is an important innovation and a major breakthrough in the country’s agricultural sector,” says Mr. hung.

FOOD SaFety

Food safety is another reason why the company opted for Marel Poultry to supply the processing solutions. Manual contact can be reduced to an absolute minimum, as products stay fully in line, while all processes are executed automatically. no manual handling is needed except for some logistic operations. In the distribution line, two more IRIS systems inspect and select product even more precisely. one system examines the back, the other the front of each product.

all this is done to guarantee the best possible end product quality and to ensure maximum food safety for consumers.

SOFtWaRe

every department makes full use of Stork solutions such as electrical stunning, killing, defeathering, evisceration, giblet harvesting, chilling, maturation, weighing/grading, inspection and cut-up. Such a state-of-the-art processing plant can’t do without an elaborate software structure. at numerous points in the process, data is collected and processed by Innova software to give a clear insight into plant performance. Furthermore, the eQM (equipment monitoring) software module displays and analyzes the performance of equipment, prompting when variances are detected and required action can be taken.

DUal lane SMaRtlIne gRaDeRS

In the grading and batching department yet more Marel solutions have been installed, examples being four dual lane Smartline graders, the last word in hygienic grading. each system has its own product group to grade: wings, drumsticks, breast pieces and thighs. as charming Food has combined these Smartline graders with Innova software, intelligent decision-making and the optimization of grading and batching results becomes easy.

gO tO: FWUSOW.cOM.tW

chaRMIng FOOD INTroduceS aIr chIllINg IN TaIwaNThe charming food greenfield project is a completely automated state-of-the-art, multi-floor, earthquake-proof poultry processing plant with a capacity of 9,000 bph (150 bpm). right from the start charming food showed a progressive approach to poultry processing, specifying Taiwan’s first air-chilling tunnel, three high-tech IrIS inspection systems and a highly elaborate Innova software control system.

FROM leFt tO RIght: Sando chen (President charming Food) receives Marel Poultry’s stainless steel chicken from Janjaap van der Mark (concluding his last project for Marel Poultry) and h.c. chen (Marel Poultry agent).

“an IMPoRtant InnoVatIon and a MaJoR bReaKthRough In the countRY’S agRIcultuRal SectoR.”

chaRMIng FOOD

charming Food is part of the Fwusow company, owned by Mr. Yao Kun hung. charming Food is one of the largest agricultural food processing businesses of taiwan with establishments all over the island. It is a vertically organized company, which started out way back in 1920 as a peanut and sesame oil processing company. bit by bit, the organization grew, adding animal feed production, feed mills, livestock farms. Recently the company opened its first processing plant.

the current design of the greenfield is fit for a capacity of 72,000 broilers per day, while the annual output will reach 20 million. the charming Food plant produces mainly fresh bulk products such as sesame chicken, Korean fried chicken and other consumer ready products. these products are supplied to b2b catering chains, restaurants and further processing companies.

• batch WeIght: 500 gR

• dISPoSItIon (PRIoRItY): 60%

• IndIVIdual WeIght: 100-140 gR

• PIeceS/batch: 2-4

• tRaY SIze: lxWxh

• StYlIng ReQuIReMentS: PaRallel

• uncut oR cutted FIlletS: MIx

• InneR FIllet: no

RecIPe a

• batch WeIght: 600 gR

• dISPoSItIon (PRIoRItY): 30%

• IndIVIdual WeIght: 90-330 gR

• PIeceS/batch: 2-6

• tRaY SIze: lxWxh

• StYlIng ReQuIReMentS: YIn-Yang

• uncut oR cutted FIlletS: onlY uncut

• InneR FIllet: no

RecIPe b

• dISPoSItIon (PRIoRItY): 20%

• gRadeS: <90 gR

• gRadeS: 90-120 gR

• gRadeS: 120-160 gR

• bulK: 5 Kg

• bulK: 10 Kg

RecIPe c

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the Robobatcher Flex has been a successful part of the Marel Poultry product range for a number of years now. as the most advanced batching system, it has already provided increased flexibility and minimized giveaway to numerous large poultry processors across europe.

next geneRatIOn

the Marel I-cut 122 Portioncutter is the next generation development from the portioning experts. It combines the high levels of accuracy, throughput and reliability of previous generations of portion cutters with the new, innovative portioning software. the I-cut 122 has been designed for cutting boneless, non-frozen poultry products to fixed weight and/or uniform dimensions. You’ll find more details about the I-cut 122 Portioncutter further on in this Insight issue.

neW batchIng cOncePt

together – and with the help of new software – these two machines now represent an entirely new intelligent batching concept.Whereas broilers are getting heavier and heavier, retail packs are getting ever smaller. at the same time, minimized giveaway and optimized product utilization are more and more at the center of efficient production processes. Marel Poultry’s new solution steps in to help processors with their daily job of making decisions.

bUSIneSS aS USUal?

at first glance, the concept looks like a straight-forward cutting and batching line. chicken breast fillets are delivered to the I-cut 122 from a filleting system. here, some of them will be cut. the cuts will be sorted out by a SpeedSort, fillets move on to the Robobatcher Flex. the Robobatcher Flex will place the suitable fillets in trays and the rest can be graded into bulk packs. It seems like business as usual.

PROactIVe

but in reality it is so much more. Full integration between the I-cut 122 and the Robobatcher Flex allows selective cutting according to specific needs from the Robobatcher. It is proactive and makes cutting decisions based on input provided in real-time for each individual breast fillet.

Integrating software is key at this point. It is the Marel Innova software that makes this whole system work. It all starts with the input given, the so called recipes. each recipe defines one job.

cUttIng accORDIng tO RecIPeS

Whenever a fillet enters the I-cut 122, it is weighed and scanned. this information is sent to the Robobatcher Flex, which decides what happens next, based on the recipes provided. If the fillet fits into one of the recipes, it will pass through without any cutting. cutting only happens if this is the only way for the fillet to fit into one of the three recipes. In that case, the I-cut 122 ensures accurate cutting, which results in high value cuts that can be used to produce nuggets. the Robobatcher Flex now finishes the job.

UnIqUe PeRFORMance

contrary to comparable systems on the market, this intelligent batching concept focuses on assessing each individual breast fillet, instead of cutting all fillets to one ideal average.

this means that giveaway is kept low, while minimal trimming ensures that processors achieve high product utilization with both fillets and trim as high value end products. this robot really does use its knife intelligently!

gO tO: MaRel.cOM/IntellIgent-batchIng

“a RObOt WIth a knIFe”INTellIgeNT poulTry baTchINg wITh robobaTcher flex aNd I-cuT 122

always on the lookout for improvements, Marel poultry can now present a new intelligent poultry batching concept combining the accuracy of the new I-cut 122 portioncutter with the top performance of a robobatcher flex. In other words a smart “robot with a knife”.

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Poland’s poultry industry is now the leading poultry producer in the eu. growth has been spectacular, from just 620,000 tons at the start of the new millennium to 2.5 million tons in 2015. exports, largely to other eu countries, account for a third of production and have increased fourfold in the last ten years. besides chicken, Poland is a major producer of turkey meat. It is also well known, particularly in germany, for its high quality goose meat products.

eU anD qaFP

a number of factors have been responsible for this success. the Polish poultry industry has taken full advantage of its geographical position and the access to major european markets given by its eu membership. to build confidence in the quality of Polish poultry products both at home and abroad, KRd, the Polish national Poultry council, introduced QaFP, a country-wide quality

assurance program. to improve their competitiveness still further, Polish poultry processors have invested heavily in new processing plants and new technology.

a PaRtneR In the lateSt technOlOgy

Marel Poultry has been happy to play a significant role in the Industry’s rapid growth and all major Marel Poultry processing systems are now in everyday operation in Poland. gP live bird handling systems, the first of which was installed over ten years ago, are in use with a number of Polish processors. the system’s containers have become a common sight on Poland’s roads.

the Stork nuova automatic evisceration and giblet harvesting system has established an enviable reputation for itself, both for the clean, hygienic way in which it works and for its ability to harvest

The choIce of leadINg proceSSorS IN eu’S largeST poulTry producINg couNTry

POlanD – a MaRel POUltRy SUcceSS StORywith its population of almost 39 million people, poland is the sixth largest in the european union. Traditionally, culinary poland is best known for its vodka and delicious sausages made in a truly huge number of varieties, largely from pig meat. In recent years, however, and particularly since accession to the european union in 2004, poland has become known for another kind of meat, poultry.

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high yield, high quality edible giblets with a minimum of labor.

ValUable tOOlS

Marel Poultry equipped plants are also using the very latest IRIS computer-controlled quality assessment systems and the latest SmartWeigher product weighing technology. together with PdS-nt/Innova software these valuable tools help processing plant management make the best possible return from each product.automatic line to line transfer, Marel end-of-line equipment and Marel Poultry software give full traceability throughout the process.

MaRel POUltRy’S bReaSt DebOnIng leaDS the FIelD

as elsewhere in the eu, Poland’s processors cut and debone a high percentage of what they produce. large volumes of breast fillet are consumed domestically and also exported.

Stork breast deboning systems have truly become the industry standard in Poland. the market boasts well over thirty Stork aMF-bx breast cap filleting systems and a number of Stork FhF-xb high-yield front half de-boning systems. Some plants boast up to four aMF-bx systems working side by side with the capacity to fillet close to 15,000 breast caps per hour.

laSt gRaMS RecOVeReD

although most Polish aMF-bx systems are producing skinless half fillets with tenderloins attached, the system will produce a large variety of other breast fillet products, whole or half, skin on or skinless. If required, tenderloins can be harvested separately and their tendons trimmed.

Recently installed Stork aMF-bx systems include breast tendon and cartilage harvesting modules. these allow the recovery of potentially valuable cartilage as well as those last grams of meat and tendon from the keel bone.

StOReD SettIngS

Polish users are enthusiastic about the system’s latest Plc controls, which allow different module settings to be stored for different breast cap weights. these make light work of adjusting the system when weights change. this is done by activating a menu on the touch screen.

all module settings are changed automatically and filleting can restart immediately.

users can, therefore, be sure of hitting the highest standards of yield, quality and product presentation regardless of the weight of breast cap being handled.

WIngStIckS

With the number of systems sold now running well into double figures, the Stork acM-nt high speed cut-up system has put down strong roots in the market.

Systems are equipped with a wide range of modules giving users optimum flexibility in the cuts they are able to offer domestic and export customers. of particular note is the first installation in a Polish processing plant of the acM-nt wingstick module.

this innovative module cuts off the inner wing joint with a bone “handle” attached, making it an ideal chicken snack.

DUckS

Marel Poultry recently commissioned the first Stork acM-nt system to work on ducks at aMI, Poland’s top exporter of goose meat products and a leading duck processor. the new system, commissioned

in January 2015 and currently cutting 4,000 ducks per hour (66 dpm), includes the JlR anatomic leg module. consistently high yield, excellent skin cover and perfect presentation are hallmarks of legs produced by the module.

MajOR PROceSSORS chOOSe MaRel POUltRy

Many Marel Poultry projects are ongoing at a number of Polish processing plants.

this article will single out one major Polish processor, whose storming growth in recent years accurately reflects Poland’s confident emergence as an eu poultry heavyweight.

lOcal cUStOMeR SUPPORt

Marel Poultry has a fully staffed corporate office in Warsaw. together with specialized technical and technological back-up from boxmeer in the netherlands, Marel Poultry is keen to provide its many Polish customers with the very best in support, allowing them to take full advantage of Poland’s rapidly growing reputation as a reliable supplier of quality poultry products.

POlanD – a MaRel POUltRy SUcceSS StORy

cedrob is a family-owned business and is completely vertically integrated. It has three processing sites and processes chicken and geese. The company produces a wide range of fresh, frozen, raw and further processed products. The continuous improvement of all processes and the optimum use of resources are key concepts for the business.

at the end of 2012, cedrob commissioned its brand new, state-of-the-art broiler processing plant at ujazdowek, not far from Warsaw. the plant was designed to handle up to 12,000 broilers per hour (200 bpm) with all primary and secondary processing equipment from Marel Poultry.

anD nOW tO 25,500 bPh

this summer will see the commissioning of a second 13,500 bph (225 bpm) plant alongside the original plant. once again, all primary and secondary processing equipment will be supplied by Marel

Poultry. a second gP containerized live bird handling system is to be installed; giblets will be harvested fully automatically by the Stork nuova automatic evisceration and giblet harvesting system.

a StUnnIng FIRSt

of particular note will be the first installation in Poland of the Stork PureSine electrical stunning system. this stunner, which conforms to the latest specific eu regulations concerning stunning, uses ac current formed into a perfect sinus over a wide range of frequencies. With this system processors can choose the frequency best suited to their particular needs, allowing stunning to be done effectively and humanely at all times and on all product weights.

State-OF-the-aRt lOgIStIcS anD cUStOMeR-FRIenDly FlexIbIlIty

after chilling, products are weighed and graded for quality using the latest Stork SmartWeigher and IRIS technologies. IRIS grades the back and front of each whole product and its anatomic portions. the SmartWeigher incorporates sophisticated control techniques which allow products to be weighed extremely accurately at the highest line speeds. one feature offered by the new system and its software will be the ability to batch whole products into standard weight 15 kg (33 lb) cartons.Products will be cut on a Stork acM-nt cut-up

system; breasts will be deboned on aMF-bx Flexcontrol systems.one noteworthy feature of the cedrob ujazdowek extension is that, after breast filleting, output from the new line will join products coming from the existing factory to give optimum flexibility in the assembly of final product packs. For optimum shelf life, particular care has been taken to ensure that products move smartly through cutting, deboning and packing departments to the cold storage.

MaRel eqUIPMent FROM StaRt tO FInISh

Packed product is checked for metal, weighed and labeled using Marel end of line equipment. Innova software follows each product through the process and ensures that information on each box, crate and pallet is captured and made available to plant management in clearly presented reports. In short, Marel’s responsibilities at cedrob ujazdowek begin on the growing farm and end only when finished product has been placed on a pallet and is ready for dispatch.

gO tO: ceDROb.cOM.Pl

ceDROb UjazDOWek DOUbleS UP

“the InneR WIng JoInt WIth a bone ‘handle’ attached, MaKIng It an Ideal chIcKen SnacK.”

neW FIlletIng DePaRtMent at aVISabORSMarT SoluTIoNS provIde eaSe aNd hIgh yIeld

after reconstruction of the entire processing plant in 2015, capacity at the portuguese processor avisabor increased to 12,000 bph (200 bpm). It was time to bring the filleting department in line with the process speed of the rest of the equipment. with the integration of two Stork aMf-bx flexcontrol systems and a Sensorx bone detection solution, breast cap deboning and bone detection have now become much easier and faster.

10

Vitor Pinho, general Manager of the processing plant, says: “We felt higher yields were possible from our product input. We were looking for an integrated deboning and filleting solution, which could fulfil our needs. Marel Poultry accepted the challenge and they really succeeded in outperforming our expectations.”

SySteMFlex

First of all, the logistics of the filleting department have to be perfect. Product should move smoothly between the different work stations in the filleting lines with minimal interruption and with minimal human intervention. the SystemFlex logistic solutions at avisabor do this perfectly, while at the same time taking good care of meat integrity and ensuring food safety. thanks to the specific belt material used, fillets do not lose meat and therefore weight when detached.

SMaRt gRaDIng WIth gaUSS

From the breast cap cut-up line, products proceed to the Marel Smartline grader.

this grader splits the product flow into two weight classes. by making flexible use of the overlap region in the gauss curve, the Smartline grader is able to divide incoming product into two equal volumes of heavy and light fillets. this is a smart way of generating the highest possible yield from the fillets, which can only be achieved with this particular combination of Marel equipment and Innova software. a single filleting line without intelligence would never match this performance.

DebOnIng

both aMF-bx Flexcontrol breast cap deboning lines at avisabor receive the same amount of fillets and are equipped with the same modules. they therefore produce the same products, one line delivering smaller fillets and the second line heavier ones.

avisabor has chosen to fully equip both Stork aMF-bx systems with modules for deskinning, wishbone removal, fillet halving, fillet separation, tendon cutting, tenderloin separation and breast tendon harvesting. In this way, the filleting

department is able to handle 14,400 fillets per hour. actual volumes are, of course, determined by the previous processes.

bOne DetectIOn

after deboning, fillets pass a manual trimming area to end up in the Marel Sensorx SmartSort. equipped with the SmartSort discharge unit, this Sensorx combines x-ray bone detection and x-ray grading in one compact solution, doing away with the need for a separate weighing unit. based on weight, SmartSort gently diverts calibrated products into a bulk box. this is avisabor’s end product: bulk batches of calibrated, bone-free, fat-free fillets, to be packed elsewhere.

challengIng PROceSS

avisabor’s state-of-the-art filleting department is a very challenging process

in which many components have to work together smoothly. Vitor Pinho comments, “after the implementation of our new filleting department, we immediately noticed huge improvements in filleting performance, compared to what we were used to. We are very pleased with this rise in yield.” “We are very satisfied with the way Marel Poultry supported us during the changes to our filleting department. that’s why we’re looking forward to continuing the cooperation in the future,” concludes Vitor Pinho.

gO tO: gRUPOlUSIaVeS.Pt

FROM leFt tO RIght:

Marco Solleveld (Marel Poultry area Sales Manager) and Vitor Pinho (general Manager avisabor). “a SIngle FIlletIng lIne WIthout IntellIgence

Would neVeR Match thIS PeRFoRMance.”

aVISabOR anD lUSIaVeS

the processing plant avisabor (former hilário, Santos & Filhos) is located in the town of estarreja, on the west coast of Portugal, 40 km (25 m) south of Porto. It was founded in 1980 to slaughter, produce and sell poultry products. In 2006 hilário became part of the lusiaves group and since then it operates under the name of avisabor. the company, with a strong expansion strategy, redid the factory lay-out in 2015, enabling a significant increase in processing capacity and ensuring its future growth.

the lusiaves group currently has 2500 employees. It is the leading Portuguese agricultural company, vertically organized and present throughout the poultry production chain, namely in corn production, animal feed, incubation of eggs and production of chicks, production of chickens, free-range chickens and turkeys, poultry processing, storage as well as sale and recovery of sub/products.

hIgh PeRFORMance WIth StORk k15

apart from redoing its filleting department, avisabor recently installed a Stork K15. Management wanted to improve the effectiveness of the killing process.they wanted to reduce manual rework, while fully complying with legislation.the Stork K15 provided the means to do this, by applying a precise cut to the end of the neck, regardless of any in-flock differences in length. besides working extremely accurately, the K15 is also very fast. It performs to the complete satisfaction of avisabor at the desired speed and capacity.

11

the new, innovative portioning software on the I-cut 122 sets the industry standard in portioning. Marel has partnered up with long-term customers to understand their primary challenges in keeping pace with constantly escalating demands from retail and food service industries. the I-cut 122 will take poultry portioning to the next level.

eVen hIgheR thROUghPUt

the dual-lane I-cut 122 offers one of the highest throughputs in the market and will match future requirements for filleting line capacities. at top performance it operates at 2000 cuts per minute per lane. on each lane, the knife ring can be positioned at four angles, 45, 60, 75 or 90 degrees.

enabling processors to make use of maximum flexibility, the cutting angles on both lanes can be adjusted independently of each other, and different cutting patterns can be cut on each lane simultaneously.

FIxeD WeIght

however, it is not just throughput that is important in processing. In many countries, retailers and food service companies are moving away from selling products of variable weight. the demand for products of consistent weight and uniform shape is increasing.

to many poultry processors the challenge is to supply retailers with fixed-weight packs, each having a specific number of portions, without the risk of being under-weight or hand over expensive give-away.

eaSy USeR InteRFace

numerous new cutting patterns and superior accuracy levels enable processors to maximize the use of raw materials, minimize give-away and increase yield. the user interface offers a very easy access to the programming, making it possible to cut products to needed target weights with maximum profit.

the software on the I-cut 122 is based on Marel’s Innova common software platform and therefore compatible with other Marel machinery.

tIMe-SaVIng

the intuitive touchscreen makes daily operation easier than ever, and users will be able to operate the machine after a short introduction. during daily production the ability to store an unlimited number of customer-specific programs in the software menu saves a lot of time. With just a few selections on the touchscreen, the programs can be applied to the production process and adjusted continuously during operation. the multi-language touchscreen allows users to switch between languages as they please. this is a big advantage for companies who have employees of different nationalities operating the machine.

IMPReSSIVely accURate

the advanced vision control technology on the I-cut 122 combined with the innovative portioning software has demonstrated impressively accurate cutting results. Standard deviations between portions are considerably lower compared to previous cutter generations.

the I-cut 122 will therefore enable poultry processors to deliver fixed-weight portions, while give-away is kept to an absolute minimum.

the I-cut 122 is a value adding portion cutter, both as a stand-alone machine and in integration with other equipment, such as the Robobatcher Flex, together creating the “Robot with a knife”.

gO tO: MaRel.cOM/IcUt122-POUltRy

The I-cut 122 portioncutter is the next generation development from Marel’s portioning experts. It combines the high levels of accuracy, throughput and reliability of previous generations of portion cutters with Marel’s new, innovative portioning software. The dual-lane I-cut 122 has been designed for cutting boneless, non-frozen poultry products to fixed weight and/or uniform dimensions.

InnOVa IntegRatIOn

the I-cut 122 perfectly integrates with Marel’s intelligent production control software Innova. Innova allows for easy-to-use remote programming, control, real-time monitoring and reporting on actual performance. Information about all pieces and portions is collected in real-time and stored in the Innova database, enabling users to analyze and optimize their portioning process.

MaIn beneFItS I-cUt 122

• Innovativecuttingpatternstomeetfuturedemands• Multi-language,intuitivetouchscreenforeasyoperation• Newvisioncontroltechnologyenablessuperioraccuracy• Dual-laneexecutionforevenhigherthroughput• Individuallyadjustablecuttinganglesoneachofthetwolanes• Infeedandoutfeedbeltswithindividuallyadjustablespeed• Designedforeasycleaningandmaintenance

I-cuT 122 porTIoNcuTTertakIng PORtIOnIng tO the next leVel

12

the Stork caS SmoothFlow stunning solution is the result of almost 20 years of controlled atmosphere Stunning practice and experience. Since its introduction it has been installed throughout europe, uSa and australia. now South america is following too.

“For Marel Poultry it’s yet another milestone to be the very first company to install controlled atmosphere stunning systems in latin america,” says lambert Rutten, Marel Poultry Sales Manager in South america.

chIle

agrosuper is known as an outstanding producer in chile and is the first ever broiler processing company in latin america to replace electrical stunning with controlled atmosphere stunning. this was a logical step, as the company’s San Vicente plant is geared up for exports, including to europe. eu regulations require processors outside the eu exporting meat to the eu to comply with similar standards to those in europe itself.

long-term Marel Poultry partner agrosuper has made a well-considered choice in opting specifically for the Stork

caS SmoothFlow controlled atmosphere stunning, together with the gP live bird handling solution. the whole system in the San Vicente plant, located 150 km (93 m) south of Santiago, consists of two complete lines for 12,000 bph (200 bpm) to replace existing crate handling and electrical stunning systems.

bRazIl

brazilian poultry processors now also recognize controlled atmosphere Stunning as the ideal solution for combining high animal welfare standards with the finest meat quality. as leading poultry processing companies in brazil also export their products to the eu, it was only a matter of time before the first company would switch to caS stunning. lambert Rutten says, “caS is an excellent way of stunning broilers with the lowest risk of bruises. In the end, processors all over the world, and in latin america too, like to benefit from less need for trimming and more yield. as of now, more and more brazilian broilers will be caS stunned and of course much improved animal welfare is also a big plus.”

gO tO: MaRel.cOM/SMOOthFlOW

caS SMooThflow bReakthROUgh In SOUth aMeRIca

The Stork caS Smoothflow stunning solution has made its breakthrough in South america, as various important poultry processors in chile and brazil have recently opted for this modern and advanced method of controlled atmosphere stunning. In their search for a more animal friendly stunning method which ensures the highest meat quality, latin american processors are now switching over to Marel poultry’s caS solution, thereby securing their exports to the eu.

What IS caS SMOOthFlOW?

the multiphase Stork caS SmoothFlow technology complies with the most stringent legislations in the world, including those of the uSda and the european union. It ensures the highest level of animal welfare and paves the way for top quality breast meat with no blood spots.

the fully automated system is available for a wide range of breeds, weights and capacities. the phases of the caS SmoothFlow process have been sharply defined and arranged to properly control the stunning with an easily and precisely programmable atmosphere. the air mixture near the broilers is continuously monitored and can be adjusted if needed via the touchscreen. In this way, the process can be programmed to a level of accuracy unequalled by other poultry stunners.

the robust construction of the Stork caS SmoothFlow concept works with a single straight-ahead belt without any transitions, making for a smoother and more welfare-friendly process. broilers are not stressed when entering the system because, in the induction phase, they lapse gently into unconsciousness thanks to an air mixture to which extremely precise levels of carbon dioxide as well as oxygen have been added. In the next phase, the stunning effect is intensified using a higher concentration of co2, which results in an irreversible stun. Visual inspection is possible through windows throughout the stunning process. consumption of co2 and o2 is limited, as the air used is recirculated.

Manual shackling after stunning is much easier, as operators don’t have to hang live, moving broilers. not only is this an ergonomic benefit, it also prevents injuries to the birds. all of these factors contribute to the best possible end product quality.

“FIRSt contRolled atMoSPheRe StunnIng SYSteMS In chIle and bRazIl.”

13

coimbatore is a city in tamil nadu state, in South India. It is a large and important industrial city experiencing steady growth. coimbatore is known for all kind of industries.

the district is home to the country’s largest concentration of cotton and clothing manufacturers as well as poultry processing industries. Most of the industries are run by creative entrepreneurs, often family-based companies looking for new opportunities.

InDUStRIal PROceSSIng

Most broilers in India are not processed in industrial plants. changing quality requirements from customers such as quick service restaurants and hotels are resulting in increasing demand for high quality processed poultry. Suprieya Foods is one of the companies which have started to process broilers industrially. Suprieya Foods used to deliver live broilers to the wet market, but the company has now taken a well thought-out, big step by integrating the entire

slaughter process in its activities and byautomating primary processing operations with Stork equipment and knowledge.

aUtOMateD PROceSS

Suprieya Foods’ completely new processing plant has an hourly capacity of 4,000 broilers (66 bpm). It uses an overhead conveyor to transport broilers through the whole process. First of all, broilers are stunned in a water bath electrical stunner. a throat cut to conform with halal regulations is then applied manually. after bleeding out, products are scalded and plucked fully automatically. Subsequently feet are removed automatically.

eVISceRatIOn

Still transported by the overhead conveyor, broilers are eviscerated in a separate room. as the last step in the evisceration process products enter the Stork neck skin inspection (cropper) machine (nIc-nt). this carousel machine helps to ensure that no crop, esophagus, trachea or thymus glands remain in the neck skin. on leaving the machine, powerful jets of water wash the outside of the product. automation helps raise production levels and contributes to an improved process and better product quality.after evisceration, products are transported to a spin chiller located in another separate room. the chiller brings products to the required core temperature. Products are then graded automatically by weight; whole products are now ready for cold storage or cut-up.

gROWIng WIth the cUStOMeR

“It is a real challenge to enter the processing business as a newcomer like we did. there’s a lot more to it than just

installing machines,” says c.V. Subramaniam, Managing director of Suprieya Foods. “We didn’t have all the knowledge and had to have complete trust in the advice and expertise of the people from Marel Poultry. We left everything in their hands; things turned out very well. now that the products have started to come out really well, I very much appreciate the work Marel Poultry has done.”

Jose Martin xavier, general Manager Marel India, adds, “to us scalability is a key factor. We see it as our mission to assist a customer like Suprieya Foods growing from an entry level plant to higher levels of automation, secondary processing and even further processing. as the poultry processor grows, we scale up too.”

a VISIOn tO gROW

to Marel Poultry it is clear that India offers huge possibilities for poultry processors like Suprieya Foods, a processor with a vision to grow. having faith in the future, this company is making a clear choice for high quality poultry processing.

Jan Wouterse, area Sales Manager for India, says, “Marel Poultry contributes to this growth, not only by providing tailor made poultry processing solutions that can grow with the processor, but also by sharing knowledge and by being present in the market. as we like to say it, ‘global knowledge, local solutions’.”

SUPRIeya FOODS MOVeS tO SeMI-aUtOMatIOn

Marel poulTry equIpS aN INdIaN greeNfIeld proceSSINg plaNT

India is one of the fastest growing markets for industrial poultry processing. Suprieya foods is a perfect example of India’s entrepreneurial spirit. Starting with industrial processing at 2,000 bph (33 bpm) and scaling up to 4,000 bph (66 bpm) is the path Suprieya has chosen to take.

abOUt SUPRIeya FOODS

Since its founding in 1993 Suprieya Foods has grown steadily. the company is involved in lots of activities such as broiler parent farms, poultry hatchery, the manufacture of poultry feeds and battery cages for broiler rearing. In 2016 the company completes its vertical integration by opening a brand new poultry processing plant in coimbatore.

c.V. Subramaniam, Managing director of Suprieya Foods.

“theRe’S a lot MoRe to It than JuSt InStallIng MachIneS.”

14

When broviand started in 1996, there was a sharp focus on producing cold cuts. consequently, the production area was designed for that way of processing. “We made a very specific choice, when deciding how to build up our production in those early days,” says broviand’s director Simon van den broek. “We wanted to do deboning by hand, which required a lot of working space. We did that to ensure the highest of standards in bone control for our cold cut products.”

bReaSt caP FIlletIng

the next step for the company was an expansion which involved the production of skin-on chicken breast fillets. With product range and throughput both growing, the production facilities needed to follow suit. In 2013, broviand invested in three Stork aMF-bx Flexcontrol breast cap filleting systems. these are known for their solid performance, excellent footprint to capacity ratio, easy operation and low cost of ownership.

an excellent PaRtneR

“Since we have started working with Marel Poultry, we have found the

company an excellent partner. With their experience in the poultry processing industry they have no problem understanding our world and can help us achieve our goals,” says Mr. van den broek. “not long ago, Marel installed a recently developed fillet separators and tendon cutters on all of our three aMFs – a great solution combining manual deboning with harvesting tenderloins without tendon.”

ManUal labOR

until recently, deboning of breast caps manually provided a limited choice of products, mainly half fillets with tenderloins attached. When tenderloins without tendon are required, a lot of expensive manual labor is usually necessary. this is because the tenderloins need to be removed manually as well as the tendon.

a neW FIllet SePaRatOR anD tenDOn cUtteR

Marel has developed a solution combining manual deboning with an efficient way of harvesting tenderloins without tendon. this is achieved by

installing a fillet separator and tendon cutter. the wishbone, together with the breast tendon, can be harvested separately with the optional breast tendon harvester. this combines the benefits of manual deboning with the advantages of semi-automatic deboning. now it is easy to process efficiently half fillets without tenderloins together with tenderloins without tendon.

MaRel gRaDeRS FOR PeRFect PackIng

Just behind the aMFs in the processing line, broviand has installed a combination of four compact graders and two Smartline graders. they are used to create bulk batches of 10 or 15 kg (22 to 33 lb) for packing in crates. on average, the Smartline graders process 6.5t per day and the compact graders 2.5t. both graders are solid performers which keep giveaway at a minimum. Simon van den broek continues, “the reliability and quality of the equipment is important to us. the compact grader is a great little machine that is very easy to use. the Smartline grader fits perfectly into our production; we have already decided that we need a third one.”

lOOkIng at the FUtURe tOgetheR

one of the next big projects for broviand is improving internal logistics. “We want to free up space and create an opportunity for highly efficient logistics,“ says Mr. van den broek. “but if we keep challenging the ways we process, can we continue to produce poultry products according to our high standards? to answer this question affirmatively, we are looking at our options and we discuss our ideas with Marel Poultry – we have built a great relationship and that is important to us.”

gO tO: bROVIanD.nl

qUalIty alWayS cOMeS FIRSt at bROVIanD

founded in 1996 by piet van den broek as a small poultry processor in the Netherlands, broviand is now a well-established player in the country, led by piet’s sons rob and Simon van den broek. The company’s general focus is on high quality end products developed together with and produced for fast food, food service and food processing companies.

SMarTlINe graderS fIT perfecTly INTo The producTIoN proceSS

“We haVe buIlt a gReat RelatIonShIP and that IS IMPoRtant to uS.”

Simon van den broek (broviand director) and Sander de bruijn (Marel Poultry Regional Sales Manager).

The new Stork vo-20 rS crosscut opener for the latin american market gives an accurate opening cut to the abdominal skin of broilers allowing for unparalleled evisceration.

In many latin american markets where whole broilers are sold for rotisserie preparation, presentation of the bird is important. broiler processors need a system that will allow them to create rotisserie-ready product with the bird in a truss position.

VeRtIcal anD hORIzOntal

the key to achieving such a presentation is in the way the opening cut is made. Rather than a traditional, vertical cut through the vent, processors in these

STork vo - 20 rS cROSScUt OPeneR

15

applications need to be able to make a horizontal cut, across the vent. this creates a bridge in the abdominal skin allowing to tuck the legs of the broiler into the cavity, making a good presentation of the product in the market.

WORlD-FaMOUS

the Vo-20 RS crosscut opener builds on the quality and performance of the world-famous Vo-20 Reference Series.

It gives processors the capability of making the required cross cut for their operations, preventing damage to the intestines and not baring the tip of the breast bone.

When combined with a Stork Vc-20 RS vent cutter and Stork eviscerator, processors will now be able to achieve highest possible yields and hygiene standards available in the industry while maintaining maximum flexibility for operations and markets.

STork vo - 20 rS cROSScUt OPeneR

In 2012 Marel poultry was invited to participate in the project to expand the existing poultry processing operation at the Malaysian company dindings poultry processing. This then evolved into a full scale greenfield project, which was completed in 2015.

as ideas evolved and proposals were developed, dindings became more and more convinced that quality, traceability and food safety must be their discriminating factors in the competitive domestic market as well as in export markets.

tWO PROceSSIng lIneS

In June 2015, dindings appointed Marel Poultry as equipment supplier for the expansion project. by then, the project had grown from an expansion to a full-blown greenfield project comprising two primary processing lines with a combined secondary processing department.

the first line is a 12,000 bph (200 bpm) line, dedicated to broiler processing and the second line – with a capacity of 6,000 bph (100bpm) – is configured to process broilers as well as female and male parent stock.

StORk SecOnDaRy DePaRtMent

the secondary department comprises a combined grading line, whole bird selection and packing areas. For cut-up, deboning and grading, dindings is operating a Stork acM-Mx fast food 8 and 9 piece cut-up line with fixed weight batching, a Stork acM-nt line with the in-line grading and batching of poultry

parts, a Stork aMF-bx Flexcontrol breast cap filleting system and a Stork thigh deboning system.

MaxIMIzeD yIelD

Working seamlessly with Mtech poultry management software already in place and with existing eRP systems, the Marel Innova production management software and Product distribution System (PdS-nt) will enable dindings to maximize their yield and throughput, conform to quality standards and also ensure food safety and full traceability.

all of these advanced poultry processing technologies will result in a considerable enhancement of overall performance.

gO tO: MFM.cOM.My

tWIce FROM gRaIn tO chIckendINdINgS’ focuS oN qualITy led To parTNerShIp wITh Marel poulTry

abOUt DInDIngS

dindings Poultry Processing Sdn bhd, part of the Malayan Flour Mills berhad, started its poultry processing activities in 1985. together with other companies in the same group, the entire supply and production chain is covered assuring strict quality control, value for money and customer satisfaction.

Malayan Flour Mill is a pioneer in its industry in Malaysia. the first – and for that time very modern – flour mill was opened in 1966 and was also referred to as “the Pride of the nation”.

gRaIn tO chIcken, Once

Just like many other integrators in the industry, the Malayan Flour Mills group entered poultry production via animal feed milling. the first MFM feed mill at lumut was launched in 1983 with the objective of producing quality feeds for the poultry and aquaculture industries. other feed mills and flour mills followed. these currently total six operations in both Malaysia and Vietnam.

gRaIn tO chIcken, tWIce

Malayan Flour Mills extended its poultry operations further up the value chain by starting its own day-old-chick production, breeder and broiler farming as well as setting up a poultry processing plant, dindings Poultry Processing Sdn bhd. It is quite unique, having production facilities from direct grain import to producing a large range of poultry products, marketed under the brand name ayam dindings.

“QualItY, tRaceabIlItY and Food SaFetY MuSt be theIR dIScRIMInatIng FactoRS.”

pou

lTry | May 2016 | eN

Marel poultry recently installed an all-new Stork Nuova polyvalent evisceration and giblet harvesting system at the les eleveurs de la champagne plant, located near reims in france. evisceration systems have to be extremely versatile in the french poultry industry, as various poultry breeds are processed.

based at caurel near Reims, the company “les eleveurs de la champagne” has been located in the heart of the champagne region for over 50 years. the company is well-known and owes its reputation to

the consistent quality of its products which also receive regular awards at the concours général agricole in Paris. the company processes a variety of poultry such as the standard chicken, red label chicken, turkey and capon.

In order to cope with the variable sizes, weights, biological shapes and other characteristics, processing solutions have to be really versatile. the evisceration process in particular presents many challenges when it comes to adapting to such variations. as label Rouge chickens are valuable, it is crucial not to damage them during evisceration.

a challengIng WeekenD

les eleveurs de la champagne didn’t want installation of the new equipment to stop production. Marel Poultry’s technicians therefore saw themselves faced with the substantial challenge of installing the new Stork eV system over a single long

weekend. the teams from eleveurs de la champagne and Marel Poultry did an excellent job in achieving this! the people of les eleveurs de la champagne were extremely satisfied with the result. all performances which were agreed beforehand were accomplished; they even exceeded expectations.

gO tO: leSVOlaIlleSDelachaMPagne.cOM

aVI aFRIca 21 - 23 Jun Johannesburg, South-africa

InDO lIVeStOck 27 - 29 Jul Jakarta, Indonesia

anUtec bRazIl 02 - 04 aug curitiba, brazil

VIV chIna 06 - 08 Sep beijing, china

MeRcOagRO 13 - 16 Sep chapeco, brazil

SaUDI agRIcUltURe 01 - 03 oct Riyadh, Saudi arabia

agROPRODMaSh 10 - 14 oct Moscow, Russia

WORlDFOOD kazakhStan 02 - 04 nov almaty, Kazakhstan

eUROtIeR 15 - 18 nov hannover, germany

POUltRy InDIa 23 - 25 nov hyderabad, India

Marel Stork Poultry Processing b.V.p.o. box 1185830 ac boxmeerThe Netherlandst +31 (0) 485 586 111f +31 (0) 485 586 222e info.poultry@marel.comw marel.com/poultry

Marel Inc.

p.o. box 1258gainesville ga 30503uSat +1 770 532 70 41f +1 770 532 57 06e usa.poultry@marel.comw marel.com/poultry

Stork poultry processing is a trade name of Marel Stork poultry processing b.v. © copyright Marel Stork poultry processing b.v., The Netherlands, 2010: all rights are reserved. any reproduction or modification of all or part of this publication, regardless of the method of reproduction or modification used and regardless of the carrier used, is strictly prohibited, unless written authorization by Marel Stork poultry processing b.v. has been obtained beforehand. Those acting in breach of this notice expose themselves to criminal and civil prosecution, in accordance with the international conventions and copyright laws. The data published herein answer to most recent information at the moment of publishing and are subject to future modifications. Stork poultry processing reserves the right to modify the construction and the execution of their products at any time without any obligation on their part to modify any equipment delivered before accordingly. The data mentioned are meant as an indication only. Stork poultry processing assumes no responsibility for errors or omissions in the data published or use of the data published. The publication of these data may not be interpreted as a warranty or guarantee of any kind (either express or implied).

SeRVIng the FRench POlyValent MaRketSTork evISceraTIoN lINe INSTalled aT leS eleveurS de la chaMpagNe

RegIOnal chIcken bReeDS

there was a point in time when local chicken races seemed to be disappearing in favor of the standard broiler. but nowadays this trend has been reversed and France now boasts many different breeds of broiler chickens. Some of them even have protected names, bound to a region, with a controlled production in an PgI geographic zone (Protected geographical Indication). this is the case with the “red label” chicken breed “Fermier de la champagne” produced by the company eleveurs de la champagne. breeding of this chicken in a defined area around Reims is mandatory. this in itself provides strong protection for both the regional market and breeders as well as associating consumers closely with products from their own region.

leS eleVeURS De la chaMPagne

les eleveurs de la champagne is a company founded in 1959 by farmers who wanted to capitalize on their expertise in chicken breeding.thanks to this original initiative, which attracted a growing number of consumers, the company has grown enormously since. Its secret to getting the best poultry products? the resources of its own region.today, the company les eleveurs de la champagne employs 175 people and has a turnover of 40 million euros. commitments remain unchanged: food safety, traceability, IFS (International Food Standard), a responsible attitude towards the environment, professional ethics and, of course, respect for animal welfare.

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