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Y 2017 | EN

poultry processingINSIGHT

CUSTOMER CASES FROM ALL OVER THE WORLD

INNOVA IMPAQT IN PRIMARY PROCESSING

SIMPLY ESSENTIALS - FIRST DF+ AIR CHILLING IN THE USA

HARIM AND MAREL POULTRY GO SKY HIGH

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Service is a continuous process that in effect never ends from our side. The way we do this, is by offering individual customizing of all service package options, from break fix service to extensive preventive maintenance, including spare part kits and software updates. A Marel Poultry service agreement is always customer specific, taking into account your requirements.

Our ability to offer the level of service, maintenance, consultancy and after-care our customers require, and even beyond, highly contributes to the recently contracted, important projects worldwide. In this edition of Insight, you can read all about various examples of such new projects in Korea, Senegal, South-East Asia, Argentina, UK and USA.

Preventive maintenance programs and service level agreements can support you in keeping your production lines running flawlessly. In this respect, Innova IMPAQT software technology is the perfect tool to keep your equipment in tip-top condition. IMPAQT delivers the key data

you need to monitor and improve current performance. You can use IMPAQT to daily analyze any primary processing machine and operate it at absolute peak level.

Poultry markets are converging globally and so virtually any end product, such as chicken feet for the Chinese market, can be produced anywhere in the world. Integrating a Stork Feet Processing System could therefore be an interesting option for many poultry processors. We offer the appropriate solutions to make feet profitable.

Duck processing is gaining more importance as duck meat becomes more popular in all parts of the world, not just the traditional Asian and Russian markets. Our modular inline cut-up system for ducks automates this process and is totally unique in the world.

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

DIRK DEN HARTOG, SERVICE DIRECTOR MAREL POULTRY

Service is the word

Unique automation of duck cut-up

Harim Korea and Marel Poultry go sky high

Catch-weight jobs with Multihead Weigher

Sedima Senegal meets the highest standards

Innova IMPAQT in primary processing

Completely new US plant - Simply Essentials has a clear vision

Superior Stork SingleFeed

South East Asian processorsopt for Marel Poultry

Maelor's brand new plant in the UK

Lizman S.A. shows exemplary growth

Profitable feet processing

Europa Cuisson's next phase

Brabant Meat streamlines the process

Versatile FHF-XB deboning modules

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CONTENTS

SERVICE IS THE WORD

poultry processingINSIGHT

Writing this preface is an excellent opportunity for me to introduce myself as the new Service Director at Marel Poultry. Assuming responsibility for our worldwide service programs, I welcome the challenge of providing you, our customers, with the highest level of service. If possible, I want to improve levels still further, paying particular attention to our preventive maintenance service programs and service level agreements.

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Marel Poultry is now able to offer duck processors an automatic modular in-line cut-up system capable of handling up to 6000 ducks per hour (100 dpm) of up to 2.8 kg (6.2 lb) eviscerated weight. The Stork ACM-NT system, developed specially for ducks, is the only one of its kind currently on the market and will handle both air and water chilled products. At this moment the new system is in successful everyday operation with duck processors in Australasia, the British Isles, Russia and Central Europe.

FLEXIBLE, MODULAR AND PRECISE

Stork ACM-NT uses the unique Stork Sigma overhead conveyor; its layout is infinitely flexible. Systems can be configured to suit the exact processing and layout requirements of each individual plant. A combination of the

unique ACM-NT shackle and turning mechanisms within the system allows products to be held and positioned perfectly for each cutting operation, resulting in optimum yield as well as top presentation and quality. The system is fully modular. If and when processing requirements change, modules can be moved or added.

TYPICAL CUTS

ACM-NT for ducks will cut carcasses into wing, front half and whole anatomic leg portions. If required, wings can be cut into separate inner and middle joint portions. In some markets wings are cut with back meat, breast meat or both attached. ACM-NT’s wing cutter can be set to give these options too. Front halves are usually filleted manually on a cone deboning line. Where a second line is installed, a Marel SmartLine grader can be used to feed each deboning line with a regular flow of sized front halves, ensuring that this important job is done as efficiently as possible. If required, the ACM-NT system can also cut breast caps.

BUTCHER QUALITY

Users are particularly impressed by the high quality of the legs cut by the system; yield and presentation are as good as when legs are butchered manually. The secret of the ACM-NT’s JL anatomic leg module is that it “pulls” rather than cuts legs from the back half. Legs retain their natural shape and there is no damage to the hip bone.

COMBINED LINE

An ACM-NT duck cut-up line can be extended upstream to accommodate a QS3 quality grading station and a

SmartWeigher. In this situation ACM-NT becomes a combined whole carcass distribution and cut-up line. On exit from the chiller, carcasses would be rehung to the ACM-NT carrier and immediately weighed and graded for quality. Automatic release stations ahead of the cutting modules would unload sized and graded carcasses needed for whole bird orders. All remaining carcasses would be cut.A combined line has a number of advantages. Carcasses no longer need to be rehung between separate processing lines, saving labor and space. A combined line also makes for a more hygienic process as product is kept in line, keeping hand to product to a minimum and preventing the build-up of buffers.

OPTIMAL MANAGEMENT

To improve processing efficiency still further, the combined line could be controlled by a single Innova PDS system. As ACM-NT cutting modules are

selectively by-passable, plant management could use Innova PDS to determine exactly how each carcass is cut, also which carcasses to release for sale whole. Quite simply, Innova PDS enables processors to match incoming carcasses in the most profitable way possible to incoming orders for whole and cut product.

CAPACITY, YIELD AND QUALITY

ACM-NT is an extremely valuable and versatile tool for duck processors everywhere. It can save labor, an increasingly important issue as hourly capacities climb. It does this, however, without compromising in any way the yield or presentation of the end product. In short, this system can truly transform the overall efficiency of a duck portioning operation.

GO TO: marel.com/duck

“STORK ACM-NT OPTIMIZES THE OVERALL EFFICIENCY OF DUCK PORTIONING.”

Duck portions make a really special meal and are becoming an increasingly common sight on the world’s dinner tables. Breast fillet, both skinless and skin-on, and legs are the most popular, although there is often a ready market for wings and crowns (bone-in front halves without wings) too. Portions are often marinated, smoked or roasted to give a tasty and convenient snack or meal component.

Stork ACM-NT features flexible, modular duck portioning

UNIQUE AUTOMATION OF DUCK CUT-UP

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Marel Poultry has been selected by the South Korean enterprise Harim Co. to be the main supplier for the modernization of the factory in the city of Iksan.

The Harim Group and Marel Poultry know each other very well, since most of Harim's plants are already equipped with many Marel Poultry solutions.

"We have great confidence in Marel Poultry and their people. We highly appreciate the cooperation and it's a pleasure working with them," says Mr. Kim, Chairman of Harim.

ONE OF THE LARGEST

It is now the turn of the Iksan factory to be completely modernized using solutions from Marel Poultry. It will be extended to six (later even to seven) lines. Two existing lines will be overhauled and reused. Four new high speed Marel Poultry lines will be installed, which will

turn this plant into one of the largest poultry processing facilities in Asia. When the seventh line becomes operational, it will be one of the largest in the world!

LATEST TECHNOLOGIES

The four new Marel Poultry lines will make use of our latest technologies in scalding, defeathering, evisceration and chilling. Stork Nuova, the world's most efficient eviscerator with integrated giblet harvesting line, will be at the heart of the evisceration department. All four lines will include low maintenance, self-calibrating high speed SmartWeighers.

20 METERS HIGH

In Korea, little land is available for building, as 75% of the country is covered by mountains. Harim cleverly solved this problem by designing a five (!) story high building, attached to the existing plant, extending their existing 80,000 m2 (861,111 sq ft) production area to

Fixed weight batching means working with a target weight for a batch, e.g. 400 g (14.1oz). Everything above the total, pre-calculated weight is considered as give-away. Most of the large retail and fast food chains demand fixed-weight batched products. Marel Multihead Weighers are ideal for producing these with absolute minimum give-away.

WHAT IS CATCH-WEIGHT?

Consumers around the world want to be able to choose from packs with various weights from e.g. 500 up to 900 g (17.6oz to 31.7oz). Small families require packs with just two pieces, while larger families might require four or more pieces. This variation on the supermarket shelf is called catch-weight.

PROCESSORS

When a supermarket asks a poultry processor for catch weight trays ranging from 500 g to 900 g it will not know in advance how these weights will be distributed. It will also not know what the day’s demand from families living in its area will be. Having taken delivery of this order, the supermarket will risk being left with unnecessary stock at the end of the day, because catch-weight trays didn't match the consumers' needs.

It is therefore a good idea for the supermarket to get to know its customers, so as to be able to predict their behavior. A loyalty program for regular clients can address this problem and help the supermarket determine in advance the right weight distribution.

PREDICTABLE CATCH-WEIGHT

Besides not knowing how weight will be distributed, a supermarket will not know how much it will have to pay for a catch-weight order until it has been actually produced and delivered. This makes catch-weight orders in principle unattractive. Innova food processing software, however, combines Marel Multihead Weigher data with

Harim Chairman Kim and Paul Cardinaal (Marel Poultry Regional Sales Manager) in Harim's headquarters with a view of the Hang river.

Supplying four new high speed lines for a five-story plantHarim and Marel Poultry go sky-high

Marel Poultry has been chosen to equip one of the world's largest poultry processing plants. The Harim company in South Korea will install four new Marel Poultry processing lines, spread over five different floors in the fully modernized Iksan plant.

INCREASING YIELDS with Marel Multihead Weigher catch-weight jobsAlthough fixed-weight batching may be on the lips of many processors nowadays, catch-weight products still represent an important part of the market. In practice, both fixed-weight and catch-weight jobs should be programmable in a processor's recipe. The multi-job software of Marel Multihead Weighers manages both calculation challenges perfectly.

Example of Marel’s catch-weight job distribution displaying the 5 different "zones” for catch-weight.

“CATCH-WEIGHT PRICE PRIOR TO THE ORDER.”

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The Marel Poultry team in front of the brand new, impressive Harim building in Iksan: Ruud Rijkers (Project Manager), Martijn Sielias (Service Area Manager), David Kim (Agent South Korea), Paul Cardinaal (Regional Sales Manager) and Dennis Lukassen (Project Engineer).

Supplying four new high speed lines for a five-story plantHarim and Marel Poultry go sky-high

with Marel Multihead Weigher catch-weight jobs

150,000 m2 (1,614,586 sq ft). Spacious air chill tunnels, which use proven Stork DownFlow "Plus" technology, will be positioned on the top floor.

A Stork overhead conveyor system distributes broilers to all departments, keeping all processes completely in-line. The system features ATC technology (Automatic Tension Control), which makes for increased reliability as well as reduced wear and tear. In Harim's Iksan plant , ATC allows a spectacular height difference of more than 20 meters (65 ft) to be bridged, necessary to reach all stories!

SOFTWARE AND MAINTENANCE

Of course, such an extensive poultry plant can't do without the necessary software control. Innova food processing software will ensure the overall monitoring of all equipment installed in the Marel Poultry lines at Harim.

Because of the size of the plant, preventive maintenance is an important issue to protect the four lines from unnecessary downtime. During the first years, Marel Poultry's field service engineers will pay regular visits to the Iksan plant, a wish clearly expressed by the Harim Group.

A VISION OF OPENNESS

Chairman Kim has a clear vision of the industry, "Harim wants to be more open about poultry processing. That is why we open our doors not only to our customers but also to students and others who are interested in poultry processing. We like to show how our high speed lines succeed in producing good quality and healthy chicken meat with a strong focus on hygiene, food safety and good working conditions." Guests entering the plant will have an impressive experience. After an introduction movie about Harim in the company cinema, the film screen will lift to give access to the Harim museum and information center. A 500 meters (1,640 ft) long visitors' corridor shows the production process and provides a complete overview of the Marel poultry processing lines.Marel Poultry is proud to be the main partner in this prestigious project, bringing poultry processing literally to new heights!

GO TO: harimgroup.com

details gathered from other equipment.It knows exactly how many trays of each catch-weight between 500 and 900 g are to be supplied and calculates the price prior to the order.

CLOSE-TO-ZERO GIVE-AWAY

Marel's catch-weight job software allows portions to be batched within a selected minimum and maximum target weight. It is therefore possible to control the final weight distribution of catch-weight trays. Thanks to Marel's Multi-job software, catch-weight becomes predictable and

supermarkets can now control their inventory of catch-weight products. This is totally unique!

Not only do customers benefit from the ability to predict catch-weight, the processor himself also profits from much lower give-away. If required, Multihead Weigher can run both catch-weight and fixed weight jobs simultaneously! In doing so, close-to-zero give-away can be achieved, since only the perfect batch enters the fixed-weight process, while the rest passes to catch-weight jobs.

ABOUT HARIMFounded in 1986, Harim is a group of companies which specialize in food, especially in protein food processing. The Harim Group splits into eight areas of activity including chicken, duck, pork, beef, feed, distribution, grain transportation and animal health care. All these production, processing and distribution businesses are closely incorporated or related to each other. The Harim Group possesses food factories in South Korea, other Asian countries and the US. The company has four poultry integrators in Korea (Harim, Orpum, Hangang CM Joowon) and one in USA (Allenharim in Seaford, Delaware). Harim Poultry is headquartered in Iksan, North Jeolla province, and processes nearly 120 million chickens annually, supplied by 600 nearby poultry farms. It employs 1,900 workers and operates multiple plants in Iksan and Jeongeup.

NAPOLEON'S HAT

Harim always strives to achieve the highest quality, respecting the most stringent food safety requirements. Bearing in mind its vision of "Global first productivity", it is logical for Harim to enter into the global market.In 2015 Chairman Kim hit the world news when he purchased Napoleon’s hat at a Paris auction. He also surprised the world by buying Pan Ocean, one of the world’s largest shipping companies with about 90 ships. Within one year Chairman Kim turned the insolvent Korean shipping company into a profitable enterprise, also transporting the majority of the feed imported by Harim.

“IT WILL BE ONE OF THE LARGEST POULTRY PROCESSING FACILITIES IN ASIA.”

MAREL CATCH-WEIGHT SOFTWARE

Marel has developed dedicated catch-weight software for Multihead Weighers. It can divide the catch-weight range from e.g. 500 to 900 g up into a maximum of 5 “zones”, where it controls how many percent of the portions must be in each weight range (see picture).This feature can help the supermarket with purchasing trays with the correct weight distribution for its local customers. At the end of the day the supermarket will not run out of a specific weight range which is in great demand nor will it be left with unsold unpopular trays.

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Almost all equipment in the primary process can feature integrated sensors to measure line performance during production time. By making use of the data from these sensors, IMPAQT can reveal which processes are causing performance losses or line stops. Based purely on data, these outcomes are fully reliable, without any guesswork involved.

One-off incidents or isolated malfunctions can always happen and are hard to prevent, but when the same malfunctions keep recurring, however small their loss may be, it is time for plant management to intervene.

IMPAQT PREVENTS DISCUSSION

Innova IMPAQT focuses on reliability. It makes key performance indicators available real-time, pointing up the

smallest losses and giving the reasons why these occurred. In this way, IMPAQT prevents discussion, allowing management to take decisions based on real data, i.e. the fully reliable and transparent data from IMPAQT.

EVISCERATION PERFORMANCE MONITORING

Once installed in a processing plant, Innova IMPAQT is the perfect tool to keep performance, availability and quality at peak level. In practice, it enables management to identify and react instantaneously to even the smallest drop in performance at the very earliest stage. Let's take evisceration performance as an example: suppose IMPAQT monitors a minor loss in evisceration performance; it can then go directly into detail to detect the causes.

INNOVA IMPAQT signals losses and their causes

An example in primary processing

Getting the highest overall effectiveness out of a processing plant is no longer achievable without solid software control. That’s exactly where IMPAQT (Intelligent Monitoring of Performance, Availability and Quality Trends), Innova's overall equipment effectiveness module, comes in. It can pinpoint the smallest undesirable production losses. Even in a very well organized and automated poultry processing plant, IMPAQT can add value.

THE SCREENS SHOW IT ALL

All IMPAQT data come together in the overarching software platform Innova. It is easy to read out this database and make reports, customized dashboards per day, week, month or year. The Innova IMPAQT screen explains it all. The “uptime bar” clearly indicates when to expect full production, taking into account break times. Production losses are shown in red with their causes. IMPAQT is a tool for signaling and generating reports and histograms; it shows areas to be addressed to eliminate possible losses. Loss can mean loss of availability (stand still or empty shackles), quality loss or performance loss.

With its new greenfield plant in Dakar, the capital of Senegal, now fully operational, Sedima is an excellent example of a professional, high capacity industrial poultry processor in West Africa. The plant has been designed for a capacity of 4,000 bph (66 bpm) and has been prepared for expansion to 6,000 bph (100 bpm).Start-up of the new plant in January 2017 was a major milestone for Sedima. The process was then optimized step by step, allowing the company to benefit from the full potential of the automated Marel Poultry solutions installed.

HIGHLY AUTOMATED

The new Sedima plant is equipped with Marel Poultry solutions, from live bird handling, electrical stunning, to scalding, defeathering, evisceration, water chilling and grading. Right from the start, the line is highly automated. Incoming broilers are hung to the line and electrically

stunned in a water bath. Next, the line makes a curve in the direction of Mecca and passes the killing station, where a manual halal kill cut is applied. This complies with the local market requirements, as 95% of the population in Senegal is Muslim.

DEFEATHERING

Products then go through the immersion scalder, followed by inline automated plucking. "We're very happy with the Stork defeathering equipment. Now that we have adjusted temperature and settings, scalding and plucking work very well, leaving exactly the right amount of epidermis which is appreciated by our market," says Khaly Sarr, Sedima Maintenance Director. Still hanging from the overhead conveyor line, products move to the evisceration department. After manual vent opening and vent cutting, evisceration is fully automated, which is the first of its kind in West Africa.

NUOVA CORETECH

Stork Nuova is recognized worldwide as a leading eviscerating system. Sedima specifically opted for the Nuova CoreTech, a 20-unit version which doesn’t rehang the viscera pack into a separate shackle, but hangs it over the back of the broiler. Afterwards the giblets can be removed and processed manually. The CoreTech version of the Nuova eviscerator offers the option of moving up to a full-function Nuova without having to replace the complete machine. Sedima's automated overhead track process is monitored by Innova PDS production control and information software, which collects all relevant product data to control production and provide dashboards.

GRADING

After being chilled off-line in a screw chiller, products are manually hung to the distribution/selection line. Whole products are graded, based on three criteria: weight, flock quality and human visual inspection. A-graded whole products find their way directly to the market, whereas all other products are cut up manually.

UP AND RUNNING

Sedima was looking for world-class processing standards and end product quality. The decision to opt for Marel was

SEDIMA meets the highest standardsWith its large integrated poultry enterprise, the long established Senegalese company Sedima is well-known for its modern and ambitious approach to the business. It has now taken the final step towards complete integration by building a greenfield processing plant from scratch, fully equipped with Marel Poultry solutions.

A modern greenfield project with a high level of automation in Senegal

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Partsreplacement

Unit revision IMPAQT

monitoring per unit

Innova IMPAQT signals even the smallest losses, detects their causes and helps keeping performance, availability and quality at maximum effectiveness.

“REAL-TIME INSIGHT TO REACH FULL POTENTIAL.”

SEDIMA meets the highest standards

“IT'S GOOD TO SEE THAT THE EQUIPMENT IS WORKING REALLY WELL.”

the result of this quest. Mrs. Anta Babacar Ngom, Sedima General Manager, says, “We are very pleased to have Marel Poultry as our main supplier. Their experienced people supported us right from the very first plans for our factory. Now that everything is up and running, it's good to see that the equipment Marel Poultry has installed is working really well. We also highly appreciate the training courses, such as the Innova PDS course, given to our personnel."

PROGRESSIVE ENTREPRENEUR

Sedima, a vertical integration, was founded in 1976 by its current President,

Mr. Babacar Ngom and is the largest privately owned agricultural company in Senegal. It covers all activities in the poultry production chain including hatcheries, breeding farms, a feed mill and a food processing factory. It is also the market leader in egg production with its own layer farms.

Sedima is a modern and progressive entrepreneur with a strong drive and a clear philosophy, qualifying it as a unique company in Africa. Hygiene, security, environment, qualified personnel, procedures and infrastructure are highly rated and respected.

POULTRY IS PROMISING

Sedima is an effective and efficient organization, turning the poultry sector into one of the most promising industries for reducing poverty and stimulating growth in Senegal. Mrs. Anta Babacar Ngom says, "We are changing the way of thinking about poultry processing in West-Africa and are showing how automation can play a role in this." Sedima is still growing and the export of poultry products to neighboring countries Mauritania, Gambia and Mali ranks highly among its priorities. Besides, the Senegalese home market, with its population of 15 million, also offers great potential.

AN OPPORTUNITY FOR POULTRY

Poultry meat consumption in Senegal is growing steadily; supermarkets and food chains are gaining ground, which will certainly boost the poultry industry. Sedima is seizing this opportunity to start up its brand new poultry processing plant in Dakar, which is prepared for future challenges.

GO TO: sedima.com

GOING INTO DETAIL

"In the graph of our example project, we can see that after having had parts replaced and been optimally set the eviscerator was already performing considerably better, but still not consistently. At that moment we could decide to make IMPAQT show performance per unit. In our example, we saw from IMPAQT that only three units were underachieving, not the entire machine. After replacing these individual units, performance was back to optimal again and fully under control,” says Dirk Kuijpers, Innova IMPAQT project coordinator. "This is a splendid example of how IMPAQT can monitor and analyze even the smallest details in order to reach full potential."

LOSS AT HANG-ON

Hang-on loss is also an important issue that can be tackled by IMPAQT, as every empty shackle at the beginning of the line comes back time and again further downstream in the process. At multiple places in the line, people and equipment will be inefficient, waiting for full shackles again. Integrating hang-on efficiency in IMPAQT means that this data is easier to gather

and is available real-time. It’s IMPAQT’s task to detect whether each empty shackle is due to poor manual performance at hang-on or not. When there is a malfunction in e.g. the live bird supply, IMPAQT should not include those empty shackles in the hang-on loss. This is possible by making use of sensors at the live bird infeed belt, registering availability.

FACE THE FACTS

How can such losses at hang-on be reduced? When IMPAQT indicates similar performance losses each time after a certain shift change, the team concerned may need a better training. Showing the IMPAQT data to the team members should be effective in stimulating them to achieve their highest hang-on performance possible. This goes to show that IMPAQT makes everybody face the facts, and the facts lead to improvement.

GO TO: marel.com/IMPAQT

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FIRST IN THE USA

Broilers are processed at the factory in Charles City, Iowa, commissioned at the end of 2016. The brand-new factory, laid out to process 8400 bph (140 bpm) of an average live weight of 2.95 kg (6.5 lb), is the first plant in the USA to be fitted out almost exclusively with Marel Poultry equipment. In the words of Simply Essential’s CEO, Dennis Krause, the Charles City operation has been set up to offer unparalleled levels of technology, efficiency, sustainability, safety and animal welfare.

CUTTING EDGE TECHNOLOGY

John Pastrana continues “After visits to reference plants in Europe and discussions with Marel Poultry specialists

and management, we came to the conclusion that Marel Poultry was best placed to give us what we wanted. We were really impressed by the performance of the equipment we saw. We are really happy to be the first company in the USA to operate the GP live bird handling system, DownFlow "Plus" air chilling, the latest Stork automatic thigh filleting technology and the 'D strap' labeler.”

EXCLUSIVELY MAREL POULTRY

The new plant also features the second SmoothFlow controlled atmosphere stunning system to be installed in the USA, a complete scalding and picking line, Nuova automatic evisceration and giblet harvesting, two complete ACM-NT automatic cut up lines, SensorX residual bone detection systems and Marel Weigh Price Labelers. Automatic rehangers transfer products from department to department, keeping the process fully in-line.

A plant-wide Innova monitoring and control system oversees the entire

production process, providing management with an invaluable management tool.

FOCUS ON ANIMAL WELFARE

“Animal welfare is a priority for us at Simply Essentials. We were particularly impressed by the Stork GP transport module which is why we chose the Stork GP live bird handling system for our new plant. Being able to load birds through the top of the module is a big improvement on the side loading we are used to in the US. We are looking forward to a big reduction in product damage and particularly in damage to wings. Wings are a popular and profitable product for us.” John Pastrana also comments on the decision to install CAS SmoothFlow, “We fully recognize the welfare and end product quality benefits of controlled atmosphere stunning and wanted this to be part of our new process. What we liked about the Stork system was its simplicity. We are sure we have made the right choice.”

EXPECTATIONS

Efficient and hygienic evisceration and giblet harvesting was another focus area for Simply Essentials. John Pastrana continues, “We decided to automate giblet harvesting, as we were convinced that this would give us significantly better giblet yields as well as saving us labor and improving hygiene. I am happy to confirm that our Nuova system is living up to expectations.”

FIRST AIR CHILLING

As already mentioned, Simply Essentials is the first poultry processor in the USA to operate a Marel Poultry DownFlow "Plus" air chill system. The chill tunnel accommodates some two miles of overhead conveyor and is able to hold some 23,000 products. It is equipped with misting devices which apply a thin film of water at various stages during the chilling process. Misting stops carcasses from drying out, keeping weight loss to a minimum. It can also inhibit the growth of bacteria. John Pastrana continues “We want to be able to offer our customers something special. We are convinced that air chilled products look and taste better. We want to lock in flavor, not water. Air chilling is also more hygienic and gives us a safer product. We are happy to promote the technology on our packaging.”

PROUD OF THIGH FILLETING

Simply Essentials is one of the first poultry processors anywhere in the world to install ACM-NT cut-up systems complete with the latest Stork automatic Thigh Fillet System. This gives retail quality deboned thigh meat at the very high throughputs handled by ACM-NT. John Pastrana continues the story, “We saw the system twice at its launch installation in Germany and were amazed at its productivity. Yield and presentation looked truly excellent and the potential for saving labor is enormous. We are proud to be the first user of the new system in the US.”Another Marel machine celebrating its US debut is the Marel M360 Labeler for the application of linerless wraparound labels. John Pastrana explains “At Simply Essentials we are keen to give our consumers full, accurate and honest information about the premium product they are buying. The M360 gives us the larger print area we need to do this.”

A JOB WELL DONE

The Simply Essentials’ project went smoothly from start to finish. An additional challenge was that the workforce of some 250 people had no prior experience of processing poultry. John Pastrana is fulsome in his praise of the support he received from Marel Poultry, “I couldn’t have wished for a better bunch of people to work with and I really can’t thank them enough. A wonderful job and well done everyone!” Marel Poultry is looking forward to working closely with Simply Essentials to ensure the success of its exciting new venture.

GO TO: simply-essentials.com

“When we started up our chicken division at the end of 2015 we had a clear vision. We wanted to offer US consumers a premium range of innovative and healthy chicken products produced to the highest standards of hygiene and animal welfare in a new factory equipped with the very latest processing technology”. With these words, John Pastrana, VP of Operations at Simply Essentials, a Kansas City based supplier of high quality protein meat and dairy products, sums his company’s aims.

Scott Moore (Marel Poultry Territory Sales Manager) and John Pastrana (Simply Essentials VP of Operations).

Simply Essentials is unique in the USA in that all its meat (beef and pork as well as chicken) comes from animals which have been fed a USDA approved flax seed based diet and is therefore lower in cholesterol and higher in Omega 3. The company’s simple motto is “if our animals eat better, so do you.” Simply Essentials is also one of only six chicken producers in the USA to

“WE WANT TO LOCK IN FLAVOR, NOT WATER.”

Simply Essentials has a clear visionMarel Poultry’s first ever complete plant in the USA

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market an air chilled fresh product. Most carcasses are cut into wing, thigh and drum portions and deboned into skinless thigh and breast fillets. All cut and deboned product is packed onto attractive lidded trays. Currently some 90% of production is sold retail through a wide range of outlets from supermarket chains to small local “Mom and Pop” stores.

COMPACT, SUPERIOR SINGULATIONSingleFeed singulatorYou can think of many situations in a poultry processing plant where products are supplied in bulk to a downstream process needing individually separate products. The brand new Stork SingleFeed singulator addresses this problem and is the answer to any situation where poultry meat supplied in bulk needs to be singulated for weighing, grading, inspection, portioning, further processing or freezing. Quite simply, it allows processors to be more effective.

The SingleFeed is suitable for small boneless products such as nuggets, tenders or strips which are supplied in bulk, batches or irregular flows. It is a high-speed automated system, so its singulation velocity can cope with highly demanding requirements. It makes use of vacuum technology to ensure the automated infeed and singulation of products. This technology demands a wet product. If products have been water-chilled, they will already be wet enough; if not the simple application of a water mist will be enough.

FLEXIBLE APPLICATIONS

The SingleFeed can be used in many different ways. It can, for example, feed belt graders (dual lane) with tenders or small boneless products. It can serve as a supply source for dual lane SensorX systems. Or it can feed dual lane nugget grading systems.No matter which task the SingleFeed performs, it always does the job quickly and consistently.

Operation and maintenance are very simple; it almost runs by itself, so to speak. The system needs few adjustments and those that are necessary such as product spacing can be done very flexibly. Because it is so easy to control, Single Feed is “simply” effective.

THE MOST COMPACT SINGULATOR

Designed to be a very compact machine, SingleFeed has a smaller footprint than other and manual alternatives. In fact, it's the most compact automated singulation solution on the market. It takes up very little space in the processing plant and saves a considerable amount of labor. In belt grader applications it can replace two to six manual operations.In all its simplicity and compactness, the SingleFeed adds significant functionality to the process with minimal need for maintenance.

GO TO: marel.com/singlefeed

“EASY CONTROL WITH HIGHEST EFFECTIVENESS.”

Simply Essentials has a clear visionMarel Poultry’s first ever complete plant in the USA

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South East Asian processorsopt for Marel Poultry

CENTACO

The Centaco Group was established in 1969 and started with a modest breeder farm. It has experienced steady growth and is now a fully, vertically integrated company, one of the leading independent agro-industry enterprises in Thailand. Centaco at present employs more than 3,000 people in 12 companies which individually excel in each of their fields, ranging from livestock breeding (both poultry and pork), farming, feed mill, animal health products, poultry processing and food production including fresh meat and further processing operations (Skyfood). 36 years ago, in 1981, Stork PMT installed a 4,000 bph (66 bpm) line at Centaco. It was Stork's first poultry processing line in South East Asia. Under the Centaco Group, CPC (Central Poultry Processing) has been supplying fresh chicken products ever since. Centaco is loyal to its start-up supplier and is going to upgrade its processing line with new Marel Poultry solutions. The upgrade consists of components and modular equipment extensions to expand the capacity of its existing line to 10,000 bph (160 bpm) as well as advanced processing equipment increasing the level of automation.

PS POULTRY COMPANY LTD.

Pongsak Group in Chonburi, Thailand has four poultry industry companies under its umbrella. The business began in the mid-50s as a small family-run chicken processing plant.

Today, its operations cover the whole spectrum of manufacturing, ranging from breeding farms to an industrial processing plant.

The company aims to process chicken into the highest quality end products, using the most advanced technologies and up-to-date know-how, which comply with general food safety regulations.

Part of this commitment is the establishment of a completely new greenfield plant with an initial capacity of 6,000 bph (100 bpm). Marel Poultry and PS Poultry have worked closely together in recent years to come to a solution, which meets performance and investment requirements for the first phase and which offers the flexibility of an upgrade to 12,000 bph (200 bpm) in the future without negatively affecting ongoing production.

ANA’S BREEDERS FARMS

Ana’s Breeders Farms Inc. (ABFI), located in Davao City in the Philippines, is a vertically integrated company consisting of breeding farms, hatchery and processing plant operations. It also has subsidiaries involved in pigs and livestock, various processed meat products, packaging products, cold storage services, and ice production. In its early beginning in 1975, it was known as Ana’s Poultry Farm, operating a rented farm of 2,000 layer hens and 2,000 broilers with only three employees.

Nowadays, Ana's Breeders Farms is one of the pioneering producers of fresh chicken in the Philippines, producing its own flagship brand “Farmer's Fresh Chicken". Two years ago, Ana's Breeders decided to considerably enlarge its processing capacity. It chose Marel Poultry for the supply of a complete processing line with a capacity of 6,000 bph (100 bpm).

This line will be installed in the modern greenfield plant which Ana's Breeders is establishing on a beautiful plot of land – surrounded by the mango trees of a former orchard.

CARGILL PHILIPPINES

Cargill Philippines formed a joint venture with Jollibee Foods Corp. (JFC) to build and operate a brand new poultry processing plant in Batangas. The new plant will be the largest of its kind in the Philippines and is expected to process 45 million chickens per year to meet increasing consumer demand.

The plant will create an estimated 1,000 new jobs and develop new opportunities in Batangas and nearby provinces, as local poultry farmers are contracted to grow chickens. The facility will provide JFC with dressed and marinated chicken to meet the growing needs of JFC brands such as Chickenjoy, Greenwich and Chowking.

The greenfield poultry processing plant in Batangas, for which Marel Poultry is the main equipment supplier, will have a capacity of 9,000 bph (150 bpm).

Greenfields and expanding plants in Thailand and the PhilippinesMany poultry processors in the South East Asian region have recently opted for Marel Poultry solutions to expand and update their processing operations. This is because Marel Poultry is very successful in translating its global experience into local solutions, tailored to customer-specific requirements. Companies like Centaco and PS Poultry in Thailand, as well as Cargill and Ana's Breeders in the Philippines have all stepped up to larger capacities or decided to build a greenfield plant using Marel Poultry solutions.

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ABOUT SALISBURY POULTRY

Salisbury Poultry is a widely recognized and reputable poultry processing company specializing in producing bespoke hand finished calibrated chicken portions. Founded in 1989 by Raj Mehta, it still remains a privately-owned company with strong family values believing that every customer is the life and blood of the business. The company began with 10 employees supplying local wholesalers and restaurants from their centrally located West Midlands base.With a dedicated workforce and leadership from Raj Mehta, the company has shown year on year growth and now operates from modern purpose built production facilities comprising of cutting halls, cold stores, holding freezers, chillers, retail packing areas, intake and distribution centers employing over 500 full time employees.

The conclusion of this agreement was one of the biggest successes for Marel Poultry during EuroTier. It involves the supply of the first, completely new, state-of-the-art plant at this line speed in the UK.

FROM CHEESE TO POULTRY

After the purchase of the former cheese dairy from “First Milk” near Wrexham in North Wales, Maelor Foods decided to transform the site into a brand new poultry slaughtering and processing plant. The plant will feature a 13,500 bph (225 bpm) broiler primary line for whole birds to serve Salisbury Poultry's Bilston factory for cut-up and deboned portions. There will

also be further deboning at the Wrexham plant itself, which has more space and more capacity for Maelor Foods to grow their business. Maelor Foods recently achieved "AA" BRC/SAI Global accreditation together with full Red Tractor Approval.

SETTING NEW STANDARDS

This is the first new, ultramodern plant to be built in the UK at this line speed; it will set new standards for the poultry industry. Marel Poultry is the chosen partner for this project

and will supply a complete slaughter and evisceration department, incorporating fully automated giblet and feet processing. Besides that, a Stork inline Air Chilling tunnel and a grading line will be installed.

FIT FOR THE FUTURE

The 13,500 bph (225 bpm) capacity is an initial start-up speed; the primary line will be prepared for future growth of Maelor Foods' operations.Jeff Donald, Marel Poultry Area Sales manager, says, "For this project Maelor Foods has selected Marel Poultry as the most capable supplier who understands their needs and has the ability to deliver a factory process fit for the future. We look forward tremendously to completing this project during 2017."

GO TO: salisburypoultry.co.uk

Maelor Foods selects Marel Poultry Brand new state-of-the-art plant

MAELOR FOODS' CHOICES

Two central themes characterize Maelor Foods' choice for Marel Poultry solutions: the utmost care for hygiene and being prepared for the highest capacities.

HYGIENE

The entire plant layout has been designed to pay the closest attention to hygiene. This already starts at the scalding process, where the Stork AeroScalder does its work with much less risk of cross-contamination than a conventional immersion scald tank. In the evisceration department, the abundant presence of extra washing devices makes a clear statement. The Nuova 24 EV carrousel, for instance, features high pressure washers, while an FIM RotoVac final inspection machine completes a hygienic evisceration process by ensuring the cleanest possible carcass. Maelor Foods also features a complete Stork Feet Processing System, hygienically handling feet in a separate overhead shackle line. It includes an advanced paw tracking system. A comprehensive Innova PDS system monitors all processes carried out in the shackle. Its sophisticated software provides full flock tracking and tracing at all times.

HIGHEST CAPACITIES

The EV department is also a clear showcase for Maelor Foods' preparedness for the highest capacities. Vent cutting, vent opening, evisceration, final inspection or rehanging; all these processes will easily handle the current 13,500 bph (225 bpm) speed. The same goes for the air chilling tunnel, which is equipped with DownFlow "Plus" technology. Maelor Foods is the first poultry processor to install the brand new ChillingControl principle, which anticipates tunnel loadings. In the distribution line, the ability to handle highest capacities is also clearly visible; newly designed, heavy-duty GDR-HS product carriers transport products through IRIS and SmartWeigher quality grading and weighing equipment to new, high capacity release stations.

Maelor Foods Ltd, a related company of Salisbury Poultry (Midlands) Ltd, has selected Marel Poultry to supply its brand new 13,500 bph (225 bpm) poultry processing plant in Wrexham, UK.

“IT WILL SET NEW STANDARDS FOR THE POULTRY INDUSTRY.”

Arie Tulp (Marel Poultry Sales and Marketing Director), Jeff Donald (Marel Poultry Area Sales Manager UK), Mr. Raj Mehta (Owner and MD of Maelor Foods), Mr. Steve Hammond (Commercial Director), Paul Cardinaal (Marel Poultry Regional Sales Manager).

12

After having enjoyed considerable growth, Lizman S.A. is now ready to expand from the Argentinian home market to a larger stage. The Stork CoreTech eviscerator fits the bill perfectly and makes it easy to move forward while making efficient and clever use of existing investments. CoreTech "lasts forever" so to speak. When expansion to a higher level of automation is required, there is no need to change the whole machine; it simply grows along with the processor!

INCREASING AUTOMATION

Lizman S.A. is progressing steadily from manual evisceration to automated processes. Together with the Nuova CoreTech eviscerator, the Vent Cutter and Vent Opener from the same Stork Nuova series are also operational in the plant. The well-known Stork Sigma overhead conveyor system with its robust trolleys and shackles transport products smoothly and reliably through the evisceration department and is also used in other processes in the Lizman S.A. plant.

FEET ON THE GROUND

Lizman S.A. sets an excellent example to many other processors in the same situation, no matter in what part of the world. The founders originate from the industry and have their feet firmly on the ground. They know their ins and outs and understand how to prevail and how to

position their company in the market to get the best results from their operations.

IMPORTANT DECISIONS

Mr. J. Carlos Guzman, Lizman S.A. General Director, says, "At the moment, we are taking important decisions regarding automation. We put all our trust in Marel Poultry, because they have the expertise and give the support. They supply the right tools for us to go further and so we can look forward to the future with a lot of optimism."

WELL DEFINED STEPS

Marco Solleveld, Marel Poultry Area Sales Manager in Argentina, is excited about the possibilities offered by the CoreTech concept. "Today you can start a processing line at 1,000 or 2,000 bph (17 or 33 bpm) with the Nuova CoreTech, operating with 10 evisceration units at 12" pitch. After a certain period of time

EXEMPLARY GROWTH Stork CoreTech grows along

The story of Lizman S.A., an Argentinian company, is typical for many poultry processors around the world who have grown from modest beginnings to an overwhelming success. In this story, the Stork Nuova CoreTech plays an important part, as it will always fit in a factory, no matter how fast it grows.

“THE CORETECH IS HERE TO STAY.” with Argentinian processor Lizman S.A.

The main market for feet is South East Asia, led by China. Depending on the market, customer demand can be for paws or for whole feet. Paws are the part of the foot the bird walks on; whole feet also include the shank up to the tarsal joint.

FOOT CUTTING

The Stork TR-DE NT defeathering to evisceration line rehanger has an integrated Feet Cutter which separates feet from the carcass. Its blade is

adjustable and can be set to give any length of foot with a larger or smaller part of shank attached. It all depends on what the customer wants.

If a perfect anatomic tarsal cut is required, it is an option to make a pre-incision with the Anatomic Tarsal Joint Pre-Cutting module, preceding the TR-DE NT.

FOOT TRACKING

Some markets demand that when a carcass is rejected at the veterinary

Added value to profitable feet productsAutomated processing of feetThe global market for feet and paws from broilers is growing steadily, making it interesting for poultry processors around the world to install feet processing systems. With its modular in-line Feet Processing System integrated into the primary process, Marel Poultry offers a complete range of options. This automated solution adds considerable value to what in the past was often seen as a by-product.

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EXEMPLARY GROWTH Stork CoreTech grows along

Mr. J. Carlos Guzman (Lizman S.A. General Director) and Marco Solleveld (Marel Poultry Area Sales Manager).

and an upgrade to 6,000 bph (100 bpm), the very same CoreTech machine can handle this speed too, using 20 units at 6" pitch. Looking even further into the future, a line speed of 9,000 bph (150 bpm) is feasible when automated giblet rehanging is integrated. So, every time they reach a new milestone, processors can continuously rely on our installed equipment and services. We support such progress in well-defined steps; we create an ongoing, smooth development, scaling up from initial capacities to higher line speeds."

Mr. J. Carlos Guzman is also enthusiastic about the Stork Nuova CoreTech. "The CoreTech is a crucial stepping stone towards automating of our processes. As we feel it now, it is here to stay."

GO TO: lizman.com.ar

ABOUT LIZMANWith more than 20 years of experience in the sector, the poultry processing company Lizman S.A. has branches in many areas of Argentina, where it develops retail sales and wholesale. The retail market, together with a sharp focus on the gastronomic and hotel market, is covered by the brand Locos X El Pollo. The Pollos Santa Monica brand is used for the wholesale market.Thanks to its policy of continuous ongoing investment, its professional team of employees and its excellent clientele, Lizman S.A. is able to keep on growing, at the same time strengthening the link with its customers. The company's own production facilities are located in the city of Pergamino, in the province of Buenos Aires, where its feed mill, processing plant and some of the breeding farms are located. This structure helps Lizman S.A. reach the table of its consumers, with products whose quality and range are permanently evolving. The company sells almost all kinds of chicken end products, such as whole products, fillets, drumsticks, legs, thighs, wings, feet, giblets and MDM meat.

with Argentinian processor Lizman S.A.

inspection in the evisceration line, its feet be rejected too. For this situation, Marel offers its feet tracking system. This consists of sensors and the necessary software. When a carcass is rejected in the evisceration department, the system registers the shackle from which the carcass has been removed. This information is then used to locate the

corresponding feet and unload them automatically from the feet line shackle.

PAW CUTTING

A paw cutter can be part of the automatic Feet Unloader. Once paws are unloaded from the shackle and conveyed to the Feet Scalder. Residual shanks are discharged from the line and collected for rendering or for use in pet food production.

FOOT SCALDING

Feet must be hard scalded. For capacities up to 12,000 bph (200 bpm) the Stork Feet Scalder L is the ideal solution. The scalder uses a rotating auger to convey feet through the scalder, containing water heated by direct steam injection.

The Stork Feet Scalder XL works on a different principle. It has a double hull through which hot water at circulates. This wall heats up the scald water in the tank; a steam supply is therefore not needed. This XL solution is suitable for the highest processing capacities.

SKINNING

Scalded feet or paws then progress to the skinning section. Depending on capacity, one to four skinners will be needed. The combination of cold and warm water, plucking fingers and water sprays inside

the peeling unit itself ensures the complete removal of skin and toenails, which are then separated from the deskinned product.

CHILLING

Once skinned, feet can be chilled. In addition to the auger chilling method in a tank with agitated water, Marel Poultry can also offer its Paddle Chiller, whose rotating tubes make use of the displacement flow principle. The Stork Paddle Chiller has a much higher loading density and unloads product in a constant flow.

ADDING VALUE

After chilling, feet have reached the end of the processing line. Now they can be assessed for quality prior to being packed as a profitable end product, ready for sale in the marketplace.

From foot/paw cutting up to and including chilling, the Stork Feet Processing System runs fully automatically. As the system adds considerable value to foot products and virtually needs no manual labor, return on investment is very quick.

GO TO: marel.com/feet

Added value to profitable feet productsDUCK FEET PROCESSING

Duck feet are profitable products as well. The principal market is located in Asia, mainly China. Duck feet processing is very similar to broiler feet processing, with the exception of scalding. Feet are scalded together with the duck itself, so there's no need for separate feet scalders. Furthermore, duck feet are never cut to paws. The Stork solution processes duck feet fully automatically up to and including peeling and chilling with various inline options. Its modular set-up enables a labor-saving, profitable solution for every production capacity.

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ABOUT EUROPA CUISSONIn 2014, all Europa Cuisson activities were centralized on a 7-hectare site in Marquain, Belgium. This highly competitive production site, certified BRC and Halal, is equipped with first-rate technologies allowing Europa Cuisson to further strengthen its foothold on international markets. “We certainly have the ambition and space to grow even more,” says Juan Mate. The company's products are marketed under the Europa Cuisson brand name as well as private labels in vacuum pasteurized packs, under controlled atmosphere and IQF frozen.

Eric de Geest (Area Sales Manager Marel Further Processing) and Juan Mate (CEO Europa Cuisson).

Juan Mate, CEO of Europa Cuisson says: “Our mission is to satisfy customer requirements by meeting their expectations with high quality products. We are known for our steamed, roasted, fried and seasoned poultry products, all available in different cuts. Our ability to innovate has led us to develop a large variety of breaded convenience products. We are convinced that these new breaded products will be successful.”

TOP TECHNOLOGY

Europa Cuisson sees the Marel RevoPortioner as the core technology it needs to be successful. For its new line of breaded chicken products, the company wanted the latest, state-of-the-art technology: “We are a leading European producer in our sector and to keep that position, we want to cooperate with providers who offer top technology”, says Juan Mate. “That's why we chose the RevoPortioner. All products have the same size and weight. There is no waste, no smearing, and the quality of raw material, such as whole muscle breast fillet, is not compromised. The fibers and the structure are as they should be. The end result is a perfectly portioned, attractive product with a good bite and great taste.”

NATURAL TENDERLOINS

Besides classics like nuggets and burgers, available in various sizes and different coatings, Europa Cuisson also offers innovative concepts. The naturally shaped tenderloin is one of them. Juan Mate continues: “We have several forming

drums for the RevoPortioner. The changeover from one drum to another is quick and easy. The Tenderloin drum is great. The products it produces look very natural. The structure is fine as well; the bite is very similar to a real tenderloin. It’s the perfect addition to our product range.”

A GOOD RELATIONSHIP

On top of delivering high-quality end products, Europa Cuisson also strives to have good, long-term partnerships with its suppliers. Juan Mate: “To me the relationship between Europa Cuisson and Marel is important. Every company wants to sell, but the Marel approach goes

beyond selling. They offer much more: they are flexible, their service is good, but above all they are a good sparring partner. For the development of our products we cooperated with the food technologists from the DemoCenter. The knowledge and experience they have at their fingertips has been very valuable. Their support is great.”

GO TO: europacuisson.com

Next phase in the success of Europa Cuisson

RevoPortioner is the perfect addition

PRACTICALLY ANY SHAPE

The RevoPortioner produces perfectly portioned poultry products at low pressure, safeguarding the texture and structure of the raw material as much as possible. The unique smoothly rotating portioning drum enables you to create products of practically any shape, including nuggets, chicken fingers, but also natural looking fillets and tenders, all with a very high weight and shape accuracy.With RevoPortioner you have virtually no loss of raw material, no defects or rework. Furthermore the total cost of ownership is very low.

With 25 years of experience in the cooked poultry meat sector, Europa Cuisson is continuously developing and adapting its range of products to meet the diverse and various needs of the food industry and catering professionals. The company has now entered the market with a completely new product line: a wide range of high-quality breaded chicken products, all made on a Marel further processing production line.

“THE END RESULT IS A PERFECTLY PORTIONED, ATTRACTIVE PRODUCT WITH A GOOD BITE AND GREAT TASTE.”

ABOUT BRABANT MEATBrabant Meat is a young company in the town of Katwijk, in the province of Noord-Brabant, Netherlands. It was founded in 2010 and employs 40 people in total. Owner John Hendriks is proud to say that staff turnover in his company is extremely low. "Our well trained workers enjoy our fine employee benefits package. People feel comfortable, so we got employees working here for more than six years." Brabant Meat specializes in processing fresh chicken products and finds its customers in Netherlands, Belgium, Germany and UK.

15

John Hendriks (Owner Brabant Meat) and Sander de Bruijn (Marel Poultry Regional Sales Manager).

Incoming products are bone-in legs, thighs and breast caps. Brabant Meat 's main business is the production of semi-finished meat products for industrial processors and food service customers. "On the other hand we sell end products to a growing group of local butchers, because they really see the difference between manual and mechanical cuts.”

WITH OR WITHOUT SKIN

Most of the time, Brabant Meat uses StreamLine for processing fresh broiler thighs. They are deboned and trimmed manually, with or without skin.

When skinless products are required, the thighs first pass through a stand-alone Marel SK skinner. John Hendriks is enthusiastic about it. “This Marel skinner works fantastically, running very reliably, without too much noise. It has a nice wide conveyor belt, a higher capacity than other skinners and no wear and tear issues.”

LOGISTIC HEAVEN

Two years ago, Brabant Meat switched to Marel StreamLine; this move resulted in a logistic heaven. "Before, we were totally surrounded by crates. We did manual cutting on a large working table and all the time, there had to be a pile of 400 kilos of meat on the table. Even before the table was empty, new meat was already being put on top of it. As a consequence the meat temperature became almost too high. From a bacteriologic perspective, StreamLine is therefore an enormous step ahead."

EXTENDED SHELF LIFE

Now, a pallet of thigh meat is guided through the skinner and StreamLine and half an hour later the products are processed and back in the chiller. "This prevents a lot of logistic problems; we don't have dirty crates anymore nor crates falling over. Furthermore, it saves a lot of hall space because it really streamlines the process. Thanks to StreamLine, the quality of the meat we

are delivering is such that we have at least an extra two days’ shelf life."

STREAMLINE DID WONDERS!

John Hendriks continues, "At first, our employees had to get accustomed to the working method. As the cut products were immediately conveyed away from the working space, there was no time anymore for a check immediately afterwards. We had to re-define the control process and bring back the routine. After that, the StreamLine did wonders for us! Our throughput per man hour grew at least 15 percent! In combination with the yield increase it couldn’t get better. We don't even need to award bonuses for hitting targets; the system itself stimulates the operators to work optimally. What is more, there's no quality inspector anymore at the end of the operation. We never have any complaints."

100 KILOS PER HOUR

Previously, using a cutting table, Brabant Meat had a maximum performance of

48 kg (105 lb) per person per hour. "Now, using StreamLine, we can easily reach 60 to 70 kg (132 to 154 lb) per hour. We can cut thighs as fast as manually loaded machines. During the time needed to position the thigh in the equipment, our skilled people will already have completely deboned the thigh; they can do 13 thighs per minute. Whenever we have the finest quality of thighs available, we can even achieve 100 kilos per hour.”

PAYROLL ACCOUNTING

For John Hendriks connecting StreamLine to Innova is logical. “Innova offers perfect control of time, kilograms, quality, throughput and yield data; it can’t be better than this! Personally I’m very fond of the Innova time registration. Everybody’s got a chip, so people check in as soon as they’re at the StreamLine and check out during breaks and end of day. You really see the effective hours and payroll accounting becomes super easy this way. We therefore rolled out Innova time registration for all our operations."

GO TO: brabantmeat.nl

StreamLining the process Brabant Meat specializes in manual deboning

“OUR THROUGHPUT PER MAN HOUR GREW AT LEAST 15 PERCENT!”

Brabant Meat is a Dutch poultry processing company specializing in the manual cut-up and deboning of broiler legs, thighs and breast caps. Since starting to use the Marel StreamLine, Brabant Meat's speed and quality can beat all manually loaded mechanical solutions, says owner John Hendriks.

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AGRIKEXPO 25 - 27 Sep Abuja, Nigeria

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Marel Inc.

P.O. Box 1258Gainesville GA 30503USAt +1 770 532 70 41f +1 770 532 57 06e usa.poultry@marel.com

Marel Stork Poultry Processing B.V.P.O. Box 118, 5830 AC BoxmeerThe Netherlandst +31 485 586 111f +31 485 586 222e info.poultry@marel.com

© Copyright Marel Stork Poultry Processing B.V., 2016: 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 prior written authorization by Marel 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. Marel 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. Marel 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 expressed or implied).

Marel is the leading global provider of advanced equipment and systems for the fish, meat and poultry industries.

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The Stork FHF-XB front half deboning system is renowned for its unbeatable yield and versatility. To enhance performance even more and meet current product quality requirements, two new modules have been developed.

The FHF-XB overhead filleting system uses product carriers which automatically position themselves in the best possible way for every module they pass. This creates ideal conditions for each step in the process, including for two new modules, the Breast Deskinner and the Back Meat Harvester.

BACK MEAT HARVESTER

Harvesting back meat is done in two steps. First, the back meat separating module detaches the left and right meat from the shoulder blades, leaving both pieces of meat hanging down from the scapula bone. Subsequently, the two circular knives of the Back Meat Harvester accurately harvest two pieces of back meat, whose meat structure remains intact. Thanks to the ingenious construction of the knives, the cut separates the meat extremely cleanly,

resulting in valuable, substantial pieces of meat, with minimal bone contamination. This FHF-XB module succeeds in preserving the structure and visual presentation of the back meat, thereby optimizing its quality and adding significant value to it. As it isn’t ground meat anymore, it can be used as a valuable source material for many more high-value purposes, even for newly developed end products.

DESKINNER

In the new FHF-XB front half Deskinner, Marel Poultry uses the proven technology of the AMF-i breast cap skinning module. Skinning performance can therefore be achieved at the highest possible level. While thoroughly removing the entire breast skin from the front halves, wing skin is left untouched. The structure of the skin removed remains intact, making it very suitable for further processed products.

The skillfully deskinned front halves are now in perfect shape for downstream operations. Their superbly smooth surface makes for an optimum visual product presentation. In this way, yield of the FHF Deskinner reaches an all-time high.

Whether fillets are produced on a Stork FHF-XB or an AMF-i system, they now are virtually exactly the same as far as product presentation is concerned. They could even be mixed for batching.

GO TO: marel.com/fhf

New Back Meat Harvester and Deskinner for FHF-XB deboning system

Versatile processing results in highest meat quality

CHECK: marel.com/

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