Taking into account the fast growing and urbanising world population, the production of poultry meat is expected to increase considerably. Processing plants need to intensify their operations to keep up with consumer demand. At the same time, the strong market drive towards lower production costs per bird with secured product quality meant that they needed to step up from 13,500 to 15,000 bph. The idea behind this is not only production speed but also keeping control of efficiency and reliability.
Marel Poultry is the world’s first supplier of integrated 15,000 bph lines. Dealing with such high speed, there is no other way than to have paramount reliability; if not, every minute of malfunctioning means 250 lost chickens. Therefore Marel Poultry has profoundly tried and tested its new 15,000 bph configuration before launching it in the market. “After thorough research and analysis, our 15,000 bph configuration hits all targets set,” says Anton de Weerd, Managing Director Marel Poultry. “Already validated in practice, it gives our customers the confidence of a proven solution.”
15,000 bph processing; a proven solution with uncompromised high efficiency and quality. Photo: Marel
Setting new standards
All systems of Marel Poultry’s 15,000 bph solution are set for this all-time high processing speed. From live bird handling with ATLAS and stunning with CAS SmoothFlow, via evisceration and chilling, up to the distribution line, every process step solidly handles this processing pace. Innova software runs in the background to supervise all fast processes plant-wide.
Marel Poultry’s 15,000 bph processing solution sets new industry standards for animal well-being, traceability, sustainability, effectiveness and product quality.
Marel Poultry’s 15,000 bph processing ensures maximum animal well-being. The combination of ATLAS live bird handling and CAS SmoothFlow anesthetisation enables a stress-free journey from farm to shackle. At all times, broilers stay in the SmartStack module until they are put gradually and painlessly to sleep. The SmartStack module has a unique Venturi floor concept for a hygienic, ventilated transport environment with the most headroom in the industry.
A chilling tunnel in a 15,000 bph processing plant can hold 45,000 products. Photo: Marel
The new LineLink transfer units underline the reliability of Marel Poultry’s 15,000 bph process. They seamlessly hand over products from one shackle type to another, while they travel through the processing stages. In addition, they also transfer all information collected on each product. Another key factor regarding reliability is active tension control (ATC); this system, unique to Marel Poultry, keeps the powerful forces of the conveyor lines under control; particularly in line bends, when shackles move at an incredible speed.
All parts of the process are geared up to effortlessly handle 15,000 bph. The defeathering department can be upgraded to process at the new higher speed and all evisceration operations can be carried out efficiently by Nuova equipment. Fully automated giblet processing at 15,000 bph is no problem either. The chilling process can also handle the high throughput levels with ease; a chilling tunnel will hold some 45,000 products, which are efficiently chilled to the required core temperature.
The entire 15,000 process is automated and inline. Strategically positioned data capture sensors, IRIS vision grading systems and SmartWeigher – the fastest accurate weigher in the world–combine to provide a wealth of useful data. This data allows Innova Food Processing Software to offer customers full forward and backward traceability. It gives a comprehensive overview of the journey of each product from live bird reception to dispatch. End-to-end traceability is central in informing customers about product quality and food safety.
The ATLAS system manages to combine most headroom in the industry with more truck load capacity and therefore reduced truck movements. Photo: Marel
Every detail of the 15,000 bph has been closely analysed to provide maximum sustainability and the lowest carbon footprint. In live bird transport, truck movements have been considerably reduced. Scalding heat is re-used and the same goes for process water. In the chilling department, precise calculations can create the perfect balance between energy savings, footprint and production costs. Advanced evisceration and cutting techniques enable processors to make best use of raw materials, resulting in a perfectly sustainable carcass balance with no useful resource wasted.
All this leads to increased efficiency and a serious impact on sustainability, since less water and energy will be used per product. In a 15,000 bph plant, each broiler’s environmental footprint will become substantially smaller.
Proven solution at Celler Land
Some time ago, Celler Land Frischgeflügel in Germany was the world’s first poultry processor to advance to a line speed of 15,000 bph. Managing Director Richard Wenneker tells about the necessity of an accelerated processing line: “Our poultry market was projected to grow. We, however, already had 2 shifts of people working and couldn’t do anymore products per day with this level of performance and quality, unless our line speed increased.”
Hendry Kuijpers, Celler Land Plant Manager adds, “Together with Marel Poultry we saw the perfect opportunity to expand the 13,500 bph capacity to 15,000.” Having processed at the new high capacity for some time now, Celler Land plant management is fully satisfied.
LineLink transfer units not only hand over products from one department to another, but also transfer data. Photo: Marel
Cranswick wants to become UK’s prime processor
For its greenfield plant in Eye, Suffolk UK, Cranswick PLC is in the process of integrating a Marel Poultry 15,000 bph processing line. “We are convinced that together we are building a magnificent plant,” says Arie Tulp, Sales and Marketing Director at Marel Poultry.
“Cranswick management wants to achieve the highest levels of throughput with the focus on turning out premium quality products. With our latest developments and cutting edge solutions we can truly make this happen. We already have a great deal of experience with installing 15,000 bph plants and have all the necessary knowledge and expertise in house. We have made sure that every step in the process can comfortably handle the high throughput. Cranswick will be able to process at optimum efficiency levels while at the same time keeping full control of the highest quality standards. There will be no compromises. The configuration chosen will most definitely help Cranswick become the UK’s prime processor.”
For the processors above, an all-time high processing speed is not a goal in itself. Already proven in practice, the fast operational pace of Marel Poultry’s 15,000 bph lines brings about a significant increase in performance and yield. Achieving lowest production costs, it is of utmost importance that the high quality and efficiency remain uncompromised.
For more information visit: marel.com/15000