50 –

1500

Hz

Up to 30% improved meat qualityPureSine Water Bath Stunner

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Marel SmartLine Grader, enhanced hygiene and serviceability

Chicken quality and technology just a start

Contents

MCheck2 Checkweigher, accuracy with flexibility, high capacity and with full wash down hygiene

SmartLine Graders offer the speed and accuracy of previous generations of Marel Graders, with greatly enhanced hygiene and serviceability. With its complete modular design, the SmartLine can be configured to meet your grading needs. The grader has an IP69K rating and can be stripped down and reas-sembled in seconds. Its unique open frame design and mini-mal horizontal surfaces ensure maximum hygiene during high-pressure wash-down. The open frame design also enables complete serviceability access.

Excellent pro-cessing tech-nology, good facilities and the best quali-ty of live chick-en at the start of the line do not guarantee an even final quality of pro-cessed chick-en. Various companies around the world, working with similar quality chicken can have totally different output. An entre-preneurial culture throughout plant personnel makes the real difference.

“We all have poultry processing passion.”

IRIS moves up

Sustainability: A key business driver

Mulithead Weigher at 2 sisters Storeboom Zeewolde: plug and play

Marel’s new MCheck 2 Checkweigher combines high levels of accuracy with flexibility and capacity, making it the ideal choice for any food processing company – with approval for process and end of line applications. The check-weigher can monitor and optimise the accuracy of processing equipment, and ensure compliance with weight legislation across a wide range of products during the post-weaning period in piglets.

> For more information go to Marel Stork

> Read more on page 3

Arie Tulp, Sales and Marketing Director,

Marel Stork Poultry Processing.

> For more information go to Marel Stork

Marel Stork Article Marel Stork

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SmartLine Graders offer the speed and accuracy of previous generations of Marel Graders, with greatly enhanced hygiene and serviceability. With its complete modular design, the SmartLine can be configured to meet your grading needs. The grader has an IP69K rating and can be stripped down and reas-sembled in seconds. Its unique open frame design and mini-mal horizontal surfaces ensure maximum hygiene during high-pressure wash-down. The open frame design also enables complete serviceability access.

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IRIS moves up

Premium quality assessment before chilling: more time to optimise your planning.

Until recently the computer controlled vision system for assess-ing product quality (Stork IRIS) would usually have been found in the pre-selection line immediately after chilling. The NEW Stork IRIS system (Intelligent Reporting, Inspection & Selection) positioned in the evisceration line gives vital information on the quality aspects of each product allowing grading now to take place at the beginning of the in-line chilling process. You therefore have both considerable extra time and tens of thou-sands of graded products in the chilling process to achieve the perfect match with your customer’s purchase orders.

Valuable quality information up to three hours earlier Many plants chill and mature products simultaneously in an in-line Stork maturation chill tunnel, as this is the best way of

ensuring top quality, tender breast fillet products. Such a tun-nel installed in a processing plant handling 13,500 broilers per hour can hold up to three hours’ production or some 40,000 products. An IRIS system installed at the end of the evisceration line can give management accurate information on incoming product quality up to three hours earlier than is currently usual. This will allow downstream production to be planned more efficiently, ensuring that each product is always put into its most profita-ble form.

Better product presentation for more accurate gradingEach product locates into a positioning wheel driven by the overhead conveyor, ensuring that its wings are perfectly pre-sented with no risk of contact with its neighbour. Products are kept strictly separate, allowing both the whole product and its individual parts to be assessed with greater accuracy. More

accurate grading means fewer mis-grades, less rework, less lost yield and more profit.

Grades both wet and dry product equally well Moving IRIS to the evisceration line has been made possible by the new system’s LED lighting and recognition software. The system, which can assess both the front and the rear of the whole product and its seven individual portions, grades wet ‘reflecting’ product just as accurately as it grades dry air chilled product.

All defects detected; red tails too The system reliably picks up broken

wings, red and blue bruises, faecal stains, residual feathers and skin damage. Two recent advances are the ability to identify red tails and ‘ignore’ red wing tips. Previously, a red wing tip could cause the whole wing to be downgrad-ed. Plants producing segmented wings discard wing tips.

Quality information stays with each product Quality information gathered by IRIS at the end of the evisceration line stays with each product on its way through chilling, pre-selection and cut-up lines. This, together with weight information from a SmartWeigher installed in the pre-selection line, will determine its final destination in the whole product packing or cut-up and de-boning departments.

IRIS in the killing and defeathering line IRIS can also be installed in the killing and defeathering line to aid veterinary inspection and act as a quality check on growers. As the system uses colour and shape to do its work, it will identify broilers which are damaged in some way, too small or have not bled out sufficiently. These can then be released automatically at the end of the killing line. The system also generates comprehensive reports on the quality of each flock, providing indisputable facts for any discussions with growers on quality issues.

IRIS, an indispensable management tool IRIS installed in the killing and evisceration lines is an invaluable tool giving plant management full information on the quality of product entering and leaving the primary process. This information can then be used to monitor grower performance, plan production more effi-ciently and react quickly and effectively to changing cir-cumstances.

Marel Stork

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Chicken quality and technology just a start

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Excellent processing technology, good facilities and the best quality of live chicken at the start of the line do not guarantee an even final quality of processed chicken. Various companies around the world, working with similar quality chicken can have totally different output. An entre-preneurial culture throughout plant personnel makes the real difference.

The lack of constant output quality or not reaching the level of quality given the input is a costly problem in the processing industry. A chicken processing plant should correctly combine and synchronize the three basic variables involved in its core business. Only if there is maximum attention for the quality of live chicken, the proper installation of equipment and used parameters depending on the characteristics of the poultry processed and a plant administration that embraces an effec-tive management model to achieve the management goals set by the company, only then can it achieve good quality and wholesomeness in its processed chicken; as well as acceptable yield and costs of the operation.Most plants are on top of their game when it comes to the quality of chicken received at the plant. The huge difference between the good and the mediocre plants measured by out-put quality is caused by managing plant personnel attitude. In contrary of what many think, the state of the art design of modern processing plants is part of the problem. Only good

management is able to identify daily behaviour that has the aspects described hereafter.

Excess comfort The technological advances to monitor the various stages of the process in a reliable way, result in the fact that many peo-ple choose to observe and evaluate the process through the different screens that the company has installed in strategic locations. Many supervisors acknowledge that the detailed quality image you see on the monitors is good enough in most cases. They justify to themselves not to change clothes and footwear, to comply with health standards, and go and look for themselves eyes on.

Lack of parameter knowledgeThe processing line operates by parameters, only with the right parameters it will reach an optimum. Despite all the advantages of digital communication systems the lack of knowledge of the right parameters is a real concern, especially because they have an enormous impact on the quality and yield. The most critical parameters of which plant personnel is often unaware: Increased time spent during stunned. The parameter is 10-12 seconds, over-scalding breasts and a Pre-chiller using water with a temperature less than 20 0C. Not having these (and other) critical control parameters top of mind with personnel in all essential positions, can have serious

implications. Even when one observes a situation seem-ingly out of control, one is not able to determine whether they should take corrective action or not. Every delay in action, even at min-imum processing speeds of 1 chicken / second (3,600 chickens / hour) becomes critical. A hesitance of just 10 seconds to reach a decision, will affect the quality and yield of 10 chickens.

Everyone in the loopGetting everyone in the loop and with the so-called program is a challenge for every operation. The described mishaps in the processing plant are not dissimilar to poultry production where staff believes that their responsibility ends when the chickens leave the farms to the processing plant. But with increasing amounts of personnel, evaluation of processes becomes more important. That starts at the farm and ends in the supermarket, with all little steps in between. A respectful recommendation for processors is to regularly visit farms to see if activities like catching, loading and feed withdrawal are done correctly.

Article

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By Eduardo Cervantes Lopez

Higher product qualitywith Stork SmoothFlow Stunning

Increase your chilling capacity, not your footprint!

Guaranteed highest yieldwith Stork breast filleting solutions

> For more information go to Marel Stork

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Sustainability: a key business driver

Sustainability is a key business driver for Marel Stork Poultry Processing. The compa-ny is keenly aware of its obligation to help protect the environment and conserve scarce resources. We live in a world where finite resources such as water and energy are coming under increasing pressure from a growing and urbanising population and from rising living standards and expecta-tions.

Our thirsty world Water is an excellent example of why we must take sustainability seriously. Over the last fifty years global water consumption has tripled. More people living in towns and increasing affluence could see water consumption triple again by 2050. As people grow more wealthy, their diet changes. They eat more meat, whose production involves large volumes of water: some 3,900 litres are needed to produce a kilo-gram of poultry meat. The latest high volume plants in Europe now use less than 10 litres (2.2 gal) per product.

Clean with less waterWater keeps equipment and the processing plant clean. Marel Stork is continuously looking for ways of doing this with less water. The Stork GP live bird handling system includes a highly effective, multi-stage container washing sys-tem where clean water supplied to rinse the containers is re-cycled to the system’s main and pre-wash stages. Product is washed at var-ious stages during primary processing. Marel Stork has introduced a technique for improv-

ing washing efficiency. Water consumption has been reduced by half with an increased clean-ing efficiency.

Process with less water: AeroScalder – a rev-olution in scalding Taking a huge step forwards in the science of scalding poultry, Marel Stork launched its revo-lutionary AeroScalder. The system uses mois-turised hot air circulated at high velocities to separate the feather pack and transfer heat to the feather follicles. It uses only a quarter of the water needed in a conventional immersion scalding system. With less water to heat up, the new system uses only half as much energy. The scalder also puts a far lower hydraulic loading on a plant’s effluent treatment system.

Process in-lineSustainability is also about ensuring the best use is made of each broiler. This is best achieved in an in-line process, equipped with IRIS for automatic quality grading and a soft-ware monitoring and control system. Broilers are quality graded and weighed at various points during the primary and secondary pro-cesses. The system allocates each individual product automatically to the downstream pro-cess best suited to its weight and quality grade, ensuring that orders are met as efficiently as possible with a minimum of mismatches. The system also highlights any process variances immediately, allowing management to take quick corrective action to avoid unnecessary waste.

Marel Stork

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The NEW labor saving LegPositioner automatically – and if needed selectively – unloads leg products from your Marel Stork cut-up system. Products are positioned perfectly on a belt conveyor, always in the same position, at the same (adjustable) pitch. The result? Labor saving unloading and smooth infeed into all possible downstream process steps.

More info? Visit marel.com/legpositioner

Call to find out more: +31 485 586 111 info.poultry@marel.com | marel.com/poultry

Simplify your leg handling

With the unique LegPositioner

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When earlier this year 2 Sisters Storteboom started looking into a batching solution to handle the growing demand for fixed-weight batches of a range of different fresh poultry products, Marel Stork Poultry Processing was the obvious partner to turn to.

“We had previously completed a Multihead Weigher pro-ject with Marel Stork for marinated chicken tenderloins and were delighted with the outcome,” says Alfons Oortwijn, the Retail Operations Manager. “Therefore, talking to them again was the obvious choice for us.”

Batching retail products Two years ago, 2 Sisters Storteboom, one of Europe’s larg-est poultry processors, started to produce and deliver a wide range of different retail products. To begin with, diced chicken, strips, drumsticks and wings were delivered to twelve supermarkets. The products proved popular with more and more supermarkets joining the list of customers which now numbers approximately 300. In order to improve the batching process and to keep up with demand, the company began to look into automating the process. Marel Stork offered its largest Multihead Weigher, one with twenty 3.5 l heads.

Forming one project group The first step was running a number of simulations. Only when these showed the achievable improvements in give-away and, indirectly, also production time and labour costs, did the project get the green light. The two companies put together a project group and work began. “Marel Stork cooperated very closely with us. Their project manager was very committed, asked all the right questions and was very hands on throughout the entire process,” says Oortwijn. “He helped us with defining the right solution, prepared every-

thing for the arrival of the equipment and spent about one and a half weeks at our processing plant during the start-up phase. It was a case of plug and play for us. When we did the very first test-run with the equipment in our plant, the resulting batches were ready for delivery.”

Pace-packing conveyor for styling bone-in products The solution now running at the Zeewolde plant since spring of this year has been designed to run different prod-ucts and make change-overs easy and straightforward. Half of the poultry being batched are boneless products (cubes and strips). These products are dropped directly into the trays and generally don’t need any further manual handling. Bone-in products, such as drumsticks and wings, make up the other half. Here the set-up is slightly different: As the bone-in products require styling by hand, the batches are delivered from the Multihead Weigher to a so-called pace-packing conveyor from which operators retrieve them and place them into trays. The trays run on a parallel conveyer at the same speed as the pace-packing conveyor. “With this Multihead Weigher installation we have been able to reduce give-away on several products as well as improve our overall performance,” says Oortwijn. “Our main challenge with this project was to re-think our production management. We really needed to be precise and create a detailed plan of what product goes on the machine and when.”

Marel Stork

Multihead Weigher at 2 Sisters Storteboom Zeewolde: plug and play

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How is your process performing?

More info? Visit marel.com/process-control

Call to fi nd out more: +31 485 586 111info.poultry@marel.commarel.com/poultry

The answer is only a click away!

Colophon

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This FOCUS edition was made by Reed Business Information’s international agricultural title World Poultry. In this FOCUS newsletter, Reed Business Information (RBI) collaborated with Marel Stork.

The primary goal of FOCUS is to provide the reader useful insights about particular themes with-in RBI’s areas of expertise, as well as those of her partners. Our goal is to provide readers, in approximately 10 minutes, a complete, in-depth update on that specific theme.

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