insight poultry processing Intelligent batching RoboBatcher Flex and I-Cut 122 may 2016 en

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1 insight poultry processing may 2016 en Intelligent batching RoboBatcher Flex and I-Cut 122 FOCUS ON POLAND CUSTOMER CASES FROM ALL OVER THE WORLD STORK NUOVA CORETECH

2 insight poultry processing This year we will be launching a new structure for the Marel brand. This edition of Insight shows you the new look. Step by step all our other communications will receive the new treatment which reflects the very latest design. CONTENTS New brand structure, commitment unchanged New brand structure Nuova CoreTech evisceration Nutrypollo SystemFlex conveyor systems that fit 5 Our activities will be grouped under the name Marel Poultry instead of Marel Stork Poultry Processing. This doesn t mean, however, that the Stork Poultry Processing brand will disappear. You will continue to find the name of Stork marked clearly on our equipment; you won't be able to pass by without noticing the Stork Poultry Processing brand on our exhibition booths, websites, advertisements and brochures. Together with the new brand structure, you ll also see our new tagline advancing food processing, because that s our core business. We want to bring food processing to the next level. We want to keep on improving. That is our passion and that's why Marel Poultry wants to continue to be the leading provider of advanced processing solutions to the global poultry industry. The year 2015 was for Marel Poultry another record year! This was due to a tailwind in a number of markets. At the same time we are well aware that this could only be accomplished thanks to the support and confidence of our customers. So we definitely won t change our commitment to support you and assist you in getting the best possible results with our systems and equipment. We strive to have even better results in We will, however, have some challenges to conquer, as the world s economic and political situation can n influence our business. But we re well prepared and well equipped to meet most of these challenges. When a national economy is booming, such as in Poland, we benefit from increasing investments by the agrifood industry in that country. In this edition of Insight you ll read all about recent developments in Poland, which in a very short time has become Europe's largest broiler processing country. Advancing food processing must also be put in the context of topical subjects such as sustainability and food safety. That s why modern poultry processing requires a focus not just on individual equipment, but even more on advanced process control. We are rolling out innovations such as fixed weight fillet processing by integrating the RoboBatcher Flex and the I-Cut 122. These overarching solutions involve the smart interaction of multiple machines. The same goes for SystemFlex conveyor logistics, connecting processes in an intelligent way. The primary goal of these innovations is to make daily processing easier and more efficient, giving a high return on investment. I wish you a good read and look forward to meeting you personally at one of our events. anton de Weerd, Managing Director Marel Poultry Charming Food introduces air chilling in Taiwan A robot with a knife Poland a Marel Poultry success story New filleting department at Avisabor I-cut 122 PortionCutter taking portioning to the next level CAS SmoothFlow breakthrough in South America Suprieya Foods moves to semi-automation Quality always comes first at Broviand Twice from grain to chicken Serving the French polyvalentmarket

3 Nuova CoreTech evisceration Serving start-ups and specific markets Processing plants need a lot of flexibility to get the most value out of their operations. The Stork Nuova CoreTech system has been developed to bring maximum evisceration efficiency to processors newly starting up or to processors who operate in markets with specific requirements. At a later point in time CoreTech can be upgraded to a full scale Nuova system. Nuova CoreTech can grow along with the processor. The Stork Nuova CoreTech technology provides evisceration solutions for all processing capacities up to 6,000 bph (100 bpm), taking into account that giblet harvesting will be done manually. Processors can have immediate access to proven technologies of the sophisticated Nuova eviscerating system without having to invest in equipment which meets the highest automation requirements and the highest line speeds. Upgrades to the CoreTech system can easily be incorporated later on, without the need to change the entire platform. As a result, the CoreTech can grow along with the processor. Easy upgrade CoreTech is the ideal solution for processors starting up who want to begin automating their evisceration process, while continuing to harvest giblets manually. In time, they can decide to upgrade the system by adding a viscera pack shackle line, allowing automated rehanging and giblet harvesting. In this way, increasing levels of automation can be integrated gradually in line with growing capacity or changes in market demands. Proven technology Built on 20 years experience, the Nuova CoreTech eviscerator offers all the advanced features today s processes demand, while providing flexibility for future needs. Function is identical to existing Nuova systems, but does not include automatic rehang of the viscera pack. CoreTech does not have separate viscera shackles, but positions the entire viscera pack over the back of the product. Exact positioning Stork s Nuova CoreTech eviscerator can cope with various line speeds and large variations in flock size and weight. The products enter the system with their backs towards the center of the carrousel. The eviscerator compensates automatically for differences in size, by positioning each broiler exactly for a perfect evisceration result, with no adjustment to settings being needed. Markets with specific needs Besides being ideally suited to processors starting up in any market in the world, Stork Nuova CoreTech will also be of interest in specific markets with cultural or religious inspection demands. That s because the viscera pack which hangs over the back of the product allows for specific veterinary inspection. When establishing the health status of a flock, inspectors find organs such as lungs, heart and liver very important. While still attached to the product, the intestine pack is visibly presented for assessment; product and organs are accessible on all sides for thorough inspection. This is crucial, as certain religions or cultures require a focus on specific organs. As such, Nuova CoreTech provides products suitable for halal, kosher and super kosher inspection procedures. The flexibility and versatility of Stork s Nuova CoreTech eviscerator will help processors just beginning with industrial poultry processing to obtain the best possible evisceration yield in all circumstances. marel.com/coretech The evisceration procedure Placed in-line after the vent opening machine, the CoreTech eviscerator is a carrousel machine with 20 units. Its task is to remove the entire viscera pack, including heart, lungs, liver, gizzard and intestines, from the body cavity in one single, automated operation. To remove the pack, a drawing arm enters the product through the abdominal cavity opening. When the arm is completely inside, it grasps the esophagus, and draws it out together with the scraped-out intestine pack. The consistent and thorough way in which the system works practically eliminates any possible damage to the intestine pack or the product itself. The drawing arm then positions the entire viscera pack over the back of the product, ensuring a high level of hygiene and aiming to prevent contamination. Hygiene Cleaning is done with great care. High pressure cleaning of parts which have been in contact with the product takes place after each operation cycle. The products themselves as well as the viscera packs are cleaned by low-pressure spray nozzles. This hygienic way of working virtually eliminates any risk of contamination. Nuova CoreTech uses considerably less water compared to conventional systems. 3

4 From left to right: On behalf of Nutrypollo: Alejandro Pineda, Francisco Guevara, Patricio Quesada (Plant Manager), Salvador and Armando Hermosillo. On behalf of Marel Poultry: Gerardo Jimenez, Edwin de Koning, Koen Serrarens and Christjan van Haperen. Nutrypollo is synonymous with total quality About Nutrypollo As a fully integrated company with a processing capacity of 12,000 bph (200 bpm), Nutrypollo has earned its position as one of Mexico s best-known poultry processing companies through their commitment to the art of the good breeder. Nutrypollo, a second generation family business, takes pride that their company is synonymous with total quality. Their commitment to quality brought a natural fit to partner with Marel Poultry to build the first demonstration plant showcasing a full Stork Poultry Processing evisceration, killing and selection line in Mexico. The project, which began in 2012, includes an entire Stork Nuova evisceration line, with giblet harvesting and handling. Additionally, Stork stunning, killing and picking solutions were installed. Confidence When the time came for expansion, Nutrypollo looked for a solutions provider that they could trust to achieve their plans of reaching capacities of 12,000 bph (200 bpm). We chose Stork Poultry Processing because the brand is known for its quality, says General Manager Cesar Quesada. The name gives us confidence. See results first Because they trusted the brand, Nutrypollo wanted to benefit from the latest in processing technologies at very high line speeds and also be the first to show Stork s equipment, solutions and performance to important Mexican customers. We see Marel Poultry as high tech and a leader in the meat processing market but we had to see results at 12,0000 bph, adds Senor Quesada. The results are in and everyone is pleased with how the line is running. Two years ago, the plant was processing 60,000 birds per day with 20 people operating in evisceration on an eight-hour shift. Now, Nutrypollo is running 80,000 birds per day, without overtime, and it only takes six hours. From their beginning as an egg laying farm in 1950 by Mr. Bernardo Quesada de Alba, father of General Director Mr. Jorge Quesada Moran, to the start of the broiler business in 1963, to their newest successes running at 12,000 bph (200 bpm), the company has enjoyed more than 50 years in the Mexican market. Their commitment to quality and seeking out the newest and highest levels of technology from partners they trust is their strategy. The success of this large expansion project and the excellent results have positioned Nutrypollo well for future plans. They want to expand their product offerings into further processed products, grow their rotisserie sales and increase their scope of supply to include some other regions of Mexico like Jalisco. Marel Poultry is committed to helping Nutrypollo to achieve their goals. The faster, the better We had invested lots of time into getting very good results from our old equipment. But we didn t know how much time we had to invest to get at least the same results with our new equipment. At first the line ran at 8,400 bph (140 bpm), but later on, we increased the speed, with new automatic harvesting equipment added. To our surprise, the faster we ran the new line the better everything worked, and finally, at full speed, we got the best results, says Marketing Director Patricio Quesada. and we are always happy to invite our customers. So they can understand that the high quality of our chicken comes from maintaining top quality in all of the processes, from hatching to distribution, and especially those processes that can really make a difference and can literally be seen and felt in our final product. We take special pride in our plant because every single customer, supplier or colleague tells us that it s the best looking and one of the most modern plants they ve ever seen, says Patricio Quesada. Service after the sale Equally important to NutryPollo is the partnership after the sale. They wanted to be sure they could maintain the equipment at a high performance level, also at higher line speeds. Here again, their trust in Marel Poultry and the mutual relationship were decisive. That s why the company signed a two-year Premium Hardware Service Level Agreement for their EV equipment, covering parts and labor. nutrypollo.com Maintaining top quality Now our processing plant is a reference of quality and innovation in our region 4

5 SystemFlex conveyor systems that fit For those who really care about adding value to a processing system, a conveyor belt is not just a simple means of transport for getting product from A to B. Marel Poultry developed the SystemFlex modular conveyor system to generate an interactive logistics environment and thereby maintain product quality and optimize process integration. The SystemFlex integrated solution is very much more than a mere transport belt. Motors and belts The focus on standardization and true quality is also reflected in the choice of motors for SystemFlex conveyors. Only three motor types are used; green labeled, efficient and reliable motors with constant torque over a very wide speed range. The conveyor motors can be connected to the central management system, in order to monitor their performance. In this way, it becomes easy to take preventive measures, such as speeding up or slowing down specific conveyors. Depending on the width required and the curves specified for the conveyor, a homogenous or modular belt material can be chosen. All belts are available in different thicknesses and pitch distances, and have the option of a middle lane or flights. They prevent product quality loss and enhance throughput. Well-designed internal logistics improve product flow, safeguarding quality in the process. A conveyor belt solution in a poultry processing plant must, therefore, address many different requirements: it must be hygienic, reliable, process embedded, flexible and silent, yet at the same time controllable and easily cleanable. The SystemFlex solution has it all. Modular flexibility By using functional, modular building blocks giving the desired height, width, length and curve, SystemFlex can solve all internal logistic issues. With a minimal number of components, i.e. 48 master building blocks, any desired, tailor-made configuration can be created. So every single processor can build an individually optimized, unique conveyor system. A SystemFlex conveyor system will always fit like a glove! Examples of the building blocks are support frames, bends, inclines (ups), declines (downs), drive and return sections. At the very minimum, the conveyor would consist of a drive end, an idle end and a support frame. Reusable components Besides the master building blocks, the clever coupling method allows for the installation of a wide range of accessory components, such as product scrapers, catch plates, infeed funnels, work surfaces, work stations, product and tray guides, cable trays, belt washing/spraying equipment and belt lifters (for optimal ease of cleaning). Should layouts change over time, almost all components can be reused, depending of course on the changed requirements. Modules are easy to install, remove and use again. There is no necessity to buy a completely new system and previously used, costly materials aren t wasted. Keeping the integrity Food safety is an overriding concern when conveying products through the plant. Besides bringing products safely and hygienically to the next process step, SystemFlex also reduces human contact with the product by automatically positioning products correctly for in-feed into a downstream machine. SystemFlex conveyor belts contribute to maintaining the integrity of products during their journey through the process. They prevent product quality loss and enhance throughput. In an ideal situation, each product is put down on the belt once only, with no need for tumbling, flipping or any further movements. Shelf life The more bare meat is tumbled, flipped or otherwise moved around during the process, the more it loses its protein, the more its adhesion force weakens, the shorter its shelf life will be. A well-handled product can reach a shelf life of 12 or 13 days; under less optimal circumstances, shelf life can be reduced to 5 days. With its strong technological background and experience in the area, Marel Poultry successfully ensures product integrity. Even if a proper, careful handling of bare fresh meat adds just one day to shelf life, this is extremely valuable for customers. Hydrophobic SystemFlex belts are built to prevent soiling; belts stay clean in almost all circumstances. As dry meat products tend to attach themselves to the belt, detaching would always leave remnants, causing the end product to lose weight. SystemFlex conveyors prevent this by using a hydrophobic coating on the belt material. Easily cleanable The SystemFlex concept meets the highest standards in safety, ergonomics and hygiene in the food industry. Its components are made from durable materials, resistant to moisture and cleaning agents. In either wet or washdown environments, safety of products and equipment is ensured. The conveyed products, raw meat or packed, are not at risk, but are always carefully treated. Product damage, loss or bulking as well as bacterial contamination can be prevented. marel.com/systemflex 5

6 An important innovation and a major breakthrough in the country s agricultural sector. Charming Food introduces air chilling in Taiwan The Charming Food greenfield project is a completely automated state-of-the-art, multi-floor, earthquake-proof poultry processing plant with a capacity of 9,000 bph (150 bpm). Right from the start Charming Food showed a progressive approach to poultry processing, specifying Taiwan s first air-chilling tunnel, three high-tech IRIS inspection systems and a highly elaborate Innova software control system. Charming Food Charming Food is part of the Fwusow company, owned by Mr. Yao Kun Hung. Charming Food is one of the largest agricultural food processing businesses of Taiwan with establishments all over the island. It is a vertically organized company, which started out way back in 1920 as a peanut and sesame oil processing company. Bit by bit, the organization grew, adding animal feed production, feed mills, livestock farms. Recently the company opened its first processing plant. The current design of the greenfield is fit for a capacity of 72,000 broilers per day, while the annual output will reach 20 million. The Charming Food plant produces mainly fresh bulk products such as sesame chicken, Korean fried chicken and other consumer ready products. These products are supplied to B2B catering chains, restaurants and further processing companies. Being a greenfield project, the Charming Food plant could start from scratch, adopting the very latest poultry processing techniques and setting new standards for Taiwan. In our search for the best possible way of automating processing on an industrial scale, we concluded that the solutions of the world s prime brand Marel Poultry met our requirements best, says Chairman Yao Kun Hung. Every single detail in the plant meets a state-of-the-art standard, such as climate control, the supply of purified water for washing and the overhead stainless steel work. Multiple floors In Taiwan, where space is very limited, Charming Food was the country s first company in years to build a greenfield project. The plant is located directly behind the company s own edible oil silos, sitting tightly between other factories in the port city of Tai Chung, on the west coast of the island. What s so special, is that the building is earthquakeproof and features multiple floors! The first floor holds the live supply, killing and evisceration departments, the control room is on the mezzanine level, while cut-up and grading lines are located on the second floor. Traceability and early grading Charming Food s strong focus on traceability starts early in the process with product being graded by an IRIS inspection system installed immediately after defeathering. The earlier each product is assessed, the easier it is to track product accurately down the line, particularly if use is also made of advanced Innova software throughout the process. IRIS grades each product individually, using size, shape, color and texture to assess defects. Grading data remains attached to product right through the process up to packaging and labeling, providing full traceability. Mr. Hung continues, It s in the interest of the consumers that traceability of food production is guaranteed all the way from the source to the end product to provide consumers with better products. Air chillling Charming Food is Taiwan s first processor to replace the traditional water cooling method with in-line air chilling equipment. With a total length of almost two kilometers (1975 m, 6480 ft) the Stork DownFlow Plus chilling tunnel, with its accurate temperature management, is able to chill product rapidly using cold air. The moisturizing cabinets, part of Stork s Plus technology moisten product surfaces to prevent dehydration and control the presentation and color desired. To us, being the first processing plant to use air cooling equipment in Taiwan, it is an important innovation and a major breakthrough in the country s agricultural sector, says Mr. Hung. Food safety Food safety is another reason why the company opted for Marel Poultry to supply the processing solutions. Manual contact can be reduced to an absolute minimum, as products stay fully in line, while all processes are executed automatically. No manual handling is needed except for some logistic operations. In the distribution line, two more IRIS systems inspect and select product even more precisely. One system examines the back, the other the front of each product. From left to right: Sando Chen (President Charming Food) receives Marel Poultry s stainless steel chicken from Janjaap van der Mark (concluding his last project for Marel Poultry) and H.C. Chen (Marel Poultry agent). All this is done to guarantee the best possible end product quality and to ensure maximum food safety for consumers. Software Every department makes full use of Stork solutions such as electrical stunning, killing, defeathering, evisceration, giblet harvesting, chilling, maturation, weighing/grading, inspection and cut-up. Such a state-of-the-art processing plant can t do without an elaborate software structure. At numerous points in the process, data is collected and processed by Innova software to give a clear insight into plant performance. Furthermore, the EQM (equipment monitoring) software module displays and analyzes the performance of equipment, prompting when variances are detected and required action can be taken. Dual Lane SmartLine Graders In the grading and batching department yet more Marel solutions have been installed, examples being four Dual Lane SmartLine Graders, the last word in hygienic grading. Each system has its own product group to grade: wings, drumsticks, breast pieces and thighs. As Charming Food has combined these SmartLine Graders with Innova software, intelligent decision-making and the optimization of grading and batching results becomes easy. fwusow.com.tw 6

7 A robot with a knife Intelligent poultry batching with RoboBatcher Flex and I-Cut 122 Always on the lookout for improvements, Marel Poultry can now present a new intelligent poultry batching concept combining the accuracy of the new I-Cut 122 PortionCutter with the top performance of a RoboBatcher Flex. In other words a smart robot with a knife. recipe A Batch weight: 500 gr Disposition (priority): 60% Individual weight: gr Pieces/batch: 2-4 Tray size: LxWxH Styling requirements: parallel Uncut or cutted fillets: mix Inner fillet: no recipe b Batch weight: 600 gr Disposition (priority): 30% Individual weight: gr Pieces/batch: 2-6 Tray size: LxWxH Styling requirements: yin-yang Uncut or cutted fillets: only uncut Inner fillet: no The RoboBatcher Flex has been a successful part of the Marel Poultry product range for a number of years now. As the most advanced batching system, it has already provided increased flexibility and minimized giveaway to numerous large poultry processors across Europe. Next generation The Marel I-Cut 122 PortionCutter is the next generation development from the portioning experts. It combines the high levels of accuracy, throughput and reliability of previous generations of portion cutters with the new, innovative portioning software. The I-Cut 122 has been designed for cutting boneless, non-frozen poultry products to fixed weight and/or uniform dimensions. You ll find more details about the I-Cut 122 PortionCutter further on in this Insight issue. New batching concept Together and with the help of new software these two machines now represent an entirely new intelligent batching concept. Whereas broilers are getting heavier and heavier, retail packs are getting ever smaller. At the same time, minimized giveaway and optimized product utilization are more and more at the center of efficient production processes. Marel Poultry s new solution steps in to help processors with their daily job of making decisions. Business as usual? At first glance, the concept looks like a straight-forward cutting and batching line. Chicken breast fillets are delivered to the I-Cut 122 from a filleting system. Here, some of them will be cut. The cuts will be sorted out by a SpeedSort, fillets move on to the RoboBatcher Flex. The RoboBatcher Flex will place the suitable fillets in trays and the rest can be graded into bulk packs. It seems like business as usual. Proactive But in reality it is so much more. Full integration between the I-Cut 122 and the RoboBatcher Flex allows selective cutting according to specific needs from the RoboBatcher. It is proactive and makes cutting decisions based on input provided in real-time for each individual breast fillet. Integrating software is key at this point. It is the Marel Innova software that makes this whole system work. It all starts with the input given, the so called recipes. Each recipe defines one job. Cutting according to recipes Whenever a fillet enters the I-Cut 122, it is weighed and scanned. This information is sent to the RoboBatcher Flex, which decides what happens next, based on the recipes provided. If the fillet fits into one of the recipes, it will pass through without any cutting. Cutting only happens if this is the only way for the fillet to fit into one of the three recipes. In that case, the I-Cut 122 ensures accurate cutting, which results in high value cuts that can be used to produce nuggets. The RoboBatcher Flex now finishes the job. Unique performance Contrary to comparable systems on the market, this intelligent batching concept focuses on assessing each individual breast fillet, instead of cutting all fillets to one ideal average. This means that giveaway is kept low, while minimal trimming ensures that processors achieve high product utilization with both fillets and trim as high value end products. This robot really does use its knife intelligently! marel.com/intelligent-batching recipe c Disposition (priority): 20% Grades: <90 gr Grades: gr Grades: gr Bulk: 5 kg Bulk: 10 kg 7

8 Poland a Marel Poultry The choice of leading processors in EU s largest poultry producing country With its population of almost 39 million people, Poland is the sixth largest in the European Union. Traditionally, culinary Poland is best known for its vodka and delicious sausages made in a truly huge number of varieties, largely from pig meat. In recent years, however, and particularly since accession to the European Union in 2004, Poland has become known for another kind of meat, poultry. Poland s poultry industry is now the leading poultry producer in the EU. Growth has been spectacular, from just 620,000 tons at the start of the new millennium to 2.5 million tons in Exports, largely to other EU countries, account for a third of production and have increased fourfold in the last ten years. Besides chicken, Poland is a major producer of turkey meat. It is also well known, particularly in Germany, for its high quality goose meat products. EU and QAFP A number of factors have been responsible for this success. The Polish poultry industry has taken full advantage of its geographical position and the access to major European markets given by its EU membership. To build confidence in the quality of Polish poultry products both at home and abroad, KRD, the Polish National Poultry Council, introduced QAFP, a country-wide quality assurance program. To improve their competitiveness still further, Polish poultry processors have invested heavily in new processing plants and new technology. A partner in the latest technology Marel Poultry has been happy to play a significant role in the Industry s rapid growth and all major Marel Poultry processing systems are now in everyday operation in Poland. GP live bird handling systems, the first of which was installed over ten years ago, are in use with a number of Polish processors. The system s containers have become a common sight on Poland s roads. The Stork Nuova automatic evisceration and giblet harvesting system has established an enviable reputation for itself, both for the clean, hygienic way in which it works and for its ability to harvest 8

9 Cedrob Ujazdowek doubles up Cedrob is a family-owned business and is completely vertically integrated. It has three processing sites and processes chicken and geese. The company produces a wide range of fresh, frozen, raw and further processed products. The continuous improvement of all processes and the optimum use of resources are key concepts for the business. At the end of 2012, Cedrob commissioned its brand new, state-of-the-art broiler processing plant at Ujazdowek, not far from Warsaw. The plant was designed to handle up to 12,000 broilers per hour (200 bpm) with all primary and secondary processing equipment from Marel Poultry. And now to 25,500 bph This summer will see the commissioning of a second 13,500 bph (225 bpm) plant alongside the original plant. Once again, all primary and secondary processing equipment will be supplied by Marel Poultry. A second GP containerized live bird handling system is to be installed; giblets will be harvested fully automatically by the Stork Nuova automatic evisceration and giblet harvesting system. A stunning first Of particular note will be the first installation in Poland of the Stork PureSine electrical stunning system. This stunner, which conforms to the latest specific EU regulations concerning stunning, uses AC current formed into a perfect sinus over a wide range of frequencies. With this system processors can choose the frequency best suited to their particular needs, allowing stunning to be done effectively and humanely at all times and on all product weights. State-of-the-art logistics and customer-friendly flexibility After chilling, products are weighed and graded for quality using the latest Stork SmartWeigher and IRIS technologies. IRIS grades the back and front of each whole product and its anatomic portions. The SmartWeigher incorporates sophisticated control techniques which allow products to be weighed extremely accurately at the highest line speeds. One feature offered by the new system and its software will be the ability to batch whole products into standard weight 15 kg (33 lb) cartons. Products will be cut on a Stork ACM-NT cut-up system; breasts will be deboned on AMF-BX FlexControl systems. One noteworthy feature of the Cedrob Ujazdowek extension is that, after breast filleting, output from the new line will join products coming from the existing factory to give optimum flexibility in the assembly of final product packs. For optimum shelf life, particular care has been taken to ensure that products move smartly through cutting, deboning and packing departments to the cold storage. Marel equipment from start to finish Packed product is checked for metal, weighed and labeled using Marel end of line equipment. Innova software follows each product through the process and ensures that information on each box, crate and pallet is captured and made available to plant management in clearly presented reports. In short, Marel s responsibilities at Cedrob Ujazdowek begin on the growing farm and end only when finished product has been placed on a pallet and is ready for dispatch. cedrob.com.pl success story high yield, high quality edible giblets with a minimum of labor. The inner wing joint with a bone handle attached, making it an ideal chicken snack. Valuable tools Marel Poultry equipped plants are also using the very latest IRIS computercontrolled quality assessment systems and the latest SmartWeigher product weighing technology. Together with PDS-NT/Innova software these valuable tools help processing plant management make the best possible return from each product. Automatic line to line transfer, Marel end-of-line equipment and Marel Poultry software give full traceability throughout the process. Marel Poultry s breast deboning leads the field As elsewhere in the EU, Poland s processors cut and debone a high percentage of what they produce. Large volumes of breast fillet are consumed domestically and also exported. Stork breast deboning systems have truly become the industry standard in Poland. The market boasts well over thirty Stork AMF-BX breast cap filleting systems and a number of Stork FHF-XB high-yield front half de-boning systems. Some plants boast up to four AMF-BX systems working side by side with the capacity to fillet close to 15,000 breast caps per hour. Last grams recovered Although most Polish AMF-BX systems are producing skinless half fillets with tenderloins attached, the system will produce a large variety of other breast fillet products, whole or half, skin on or skinless. If required, tenderloins can be harvested separately and their tendons trimmed. Recently installed Stork AMF-BX systems include breast tendon and cartilage harvesting modules. These allow the recovery of potentially valuable cartilage as well as those last grams of meat and tendon from the keel bone. Stored settings Polish users are enthusiastic about the system s latest PLC controls, which allow different module settings to be stored for different breast cap weights. These make light work of adjusting the system when weights change. This is done by activating a menu on the touch screen. All module settings are changed automatically and filleting can restart immediately. Users can, therefore, be sure of hitting the highest standards of yield, quality and product presentation regardless of the weight of breast cap being handled. Wingsticks With the number of systems sold now running well into double figures, the Stork ACM-NT high speed cut-up system has put down strong roots in the market. Systems are equipped with a wide range of modules giving users optimum flexibility in the cuts they are able to offer domestic and export customers. Of particular note is the first installation in a Polish processing plant of the ACM-NT wingstick module. This innovative module cuts off the inner wing joint with a bone handle attached, making it an ideal chicken snack. Ducks Marel Poultry recently commissioned the first Stork ACM-NT system to work on ducks at AMI, Poland s top exporter of goose meat products and a leading duck processor. The new system, commissioned in January 2015 and currently cutting 4,000 ducks per hour (66 dpm), includes the JLR anatomic leg module. Consistently high yield, excellent skin cover and perfect presentation are hallmarks of legs produced by the module. Major processors choose Marel Poultry Many Marel Poultry projects are ongoing at a number of Polish processing plants. This article will single out one major Polish processor, whose storming growth in recent years accurately reflects Poland s confident emergence as an EU poultry heavyweight. Local customer support Marel Poultry has a fully staffed corporate office in Warsaw. Together with specialized technical and technological back-up from Boxmeer in the Netherlands, Marel Poultry is keen to provide its many Polish customers with the very best in support, allowing them to take full advantage of Poland s rapidly growing reputation as a reliable supplier of quality poultry products. 9

10 New filleting department at Avisabor Smart solutions provide ease and high yield From left to right: Marco Solleveld (Marel Poultry Area Sales Manager) and Vitor Pinho (General Manager Avisabor). After reconstruction of the entire processing plant in 2015, capacity at the Portuguese processor Avisabor increased to 12,000 bph (200 bpm). It was time to bring the filleting department in line with the process speed of the rest of the equipment. With the integration of two Stork AMF- BX FlexControl systems and a SensorX bone detection solution, breast cap deboning and bone detection have now become much easier and faster. A single filleting line without intelligence would never match this performance. Avisabor and Lusiaves The processing plant Avisabor (former Hilário, Santos & Filhos) is located in the town of Estarreja, on the west coast of Portugal, 40 km (25 m) south of Porto. It was founded in 1980 to slaughter, produce and sell poultry products. In 2006 Hilário became part of the Lusiaves Group and since then it operates under the name of Avisabor. The company, with a strong expansion strategy, redid the factory lay-out in 2015, enabling a significant increase in processing capacity and ensuring its future growth. The Lusiaves Group currently has 2500 employees. It is the leading Portuguese agricultural company, vertically organized and present throughout the poultry production chain, namely in corn production, animal feed, incubation of eggs and production of chicks, production of chickens, free-range chickens and turkeys, poultry processing, storage as well as sale and recovery of sub/products. Vitor Pinho, General Manager of the processing plant, says: We felt higher yields were possible from our product input. We were looking for an integrated deboning and filleting solution, which could fulfil our needs. Marel Poultry accepted the challenge and they really succeeded in outperforming our expectations. SystemFlex First of all, the logistics of the filleting department have to be perfect. Product should move smoothly between the different work stations in the filleting lines with minimal interruption and with minimal human intervention. The SystemFlex logistic solutions at Avisabor do this perfectly, while at the same time taking good care of meat integrity and ensuring food safety. Thanks to the specific belt material used, fillets do not lose meat and therefore weight when detached. Smart grading with Gauss From the breast cap cut-up line, products proceed to the Marel SmartLine Grader. This grader splits the product flow into two weight classes. By making flexible use of the overlap region in the Gauss curve, the SmartLine Grader is able to divide incoming product into two equal volumes of heavy and light fillets. This is a smart way of generating the highest possible yield from the fillets, which can only be achieved with this particular combination of Marel equipment and Innova software. A single filleting line without intelligence would never match this performance. Deboning Both AMF-BX FlexControl breast cap deboning lines at Avisabor receive the same amount of fillets and are equipped with the same modules. They therefore produce the same products, one line delivering smaller fillets and the second line heavier ones. Avisabor has chosen to fully equip both Stork AMF-BX systems with modules for deskinning, wishbone removal, fillet halving, fillet separation, tendon cutting, tenderloin separation and breast tendon harvesting. In this way, the filleting department is able to handle 14,400 fillets per hour. Actual volumes are, of course, determined by the previous processes. Bone detection After deboning, fillets pass a manual trimming area to end up in the Marel SensorX SmartSort. Equipped with the SmartSort discharge unit, this SensorX combines X-ray bone detection and X-ray grading in one compact solution, doing away with the need for a separate weighing unit. Based on weight, SmartSort gently diverts calibrated products into a bulk box. This is Avisabor s end product: bulk batches of calibrated, bone-free, fat-free fillets, to be packed elsewhere. Challenging process Avisabor s state-of-the-art filleting department is a very challenging process in which many components have to work together smoothly. Vitor Pinho comments, After the implementation of our new filleting department, we immediately noticed huge improvements in filleting performance, compared to what we were used to. We are very pleased with this rise in yield. We are very satisfied with the way Marel Poultry supported us during the changes to our filleting department. That s why we re looking forward to continuing the cooperation in the future, concludes Vitor Pinho. grupolusiaves.pt High performance with Stork K15 Apart from redoing its filleting department, Avisabor recently installed a Stork K15. Management wanted to improve the effectiveness of the killing process.they wanted to reduce manual rework, while fully complying with legislation.the Stork K15 provided the means to do this, by applying a precise cut to the end of the neck, regardless of any in-flock differences in length. Besides working extremely accurately, the K15 is also very fast. It performs to the complete satisfaction of Avisabor at the desired speed and capacity. 10

11 Main benefits I-Cut 122 Innovative cutting patterns to meet future demands Multi-language, intuitive touchscreen for easy operation New vision control technology enables superior accuracy Dual-lane execution for even higher throughput Individually adjustable cutting angles on each of the two lanes Infeed and outfeed belts with individually adjustable speed Designed for easy cleaning and maintenance I-Cut 122 PortionCutter Taking portioning to the next level The I-Cut 122 PortionCutter is the next generation development from Marel s portioning experts. It combines the high levels of accuracy, throughput and reliability of previous generations of portion cutters with Marel s new, innovative portioning software. The dual-lane I-Cut 122 has been designed for cutting boneless, non-frozen poultry products to fixed weight and/or uniform dimensions. The new, innovative portioning software on the I-Cut 122 sets the industry standard in portioning. Marel has partnered up with long-term customers to understand their primary challenges in keeping pace with constantly escalating demands from retail and food service industries. The I-Cut 122 will take poultry portioning to the next level. Even higher throughput The dual-lane I-Cut 122 offers one of the highest throughputs in the market and will match future requirements for filleting line capacities. At top performance it operates at 2000 cuts per minute per lane. On each lane, the knife ring can be positioned at four angles, 45, 60, 75 or 90 degrees. Enabling processors to make use of maximum flexibility, the cutting angles on both lanes can be adjusted independently of each other, and different cutting patterns can be cut on each lane simultaneously. Fixed weight However, it is not just throughput that is important in processing. In many countries, retailers and food service companies are moving away from selling products of variable weight. The demand for products of consistent weight and uniform shape is increasing. To many poultry processors the challenge is to supply retailers with fixed-weight packs, each having a specific number of portions, without the risk of being under-weight or hand over expensive give-away. Easy user interface Numerous new cutting patterns and superior accuracy levels enable processors to maximize the use of raw materials, minimize give-away and increase yield. The user interface offers a very easy access to the programming, making it possible to cut products to needed target weights with maximum profit. The software on the I-Cut 122 is based on Marel s Innova common software platform and therefore compatible with other Marel machinery. Time-saving The intuitive touchscreen makes daily operation easier than ever, and users will be able to operate the machine after a short introduction. During daily production the ability to store an unlimited number of customer-specific programs in the software menu saves a lot of time. With just a few selections on the touchscreen, the programs can be applied to the production process and adjusted continuously during operation. The multi-language touchscreen allows users to switch between languages as they please. This is a big advantage for companies who have employees of different nationalities operating the machine. Innova integration Impressively accurate The advanced vision control technology on the I-Cut 122 combined with the innovative portioning software has demonstrated impressively accurate cutting results. Standard deviations between portions are considerably lower compared to previous cutter generations. The I-Cut 122 will therefore enable poultry processors to deliver fixed-weight portions, while give-away is kept to an absolute minimum. The I-Cut 122 is a value adding portion cutter, both as a stand-alone machine and in integration with other equipment, such as the RoboBatcher Flex, together creating the Robot with a knife. marel.com/icut122-poultry The I-Cut 122 perfectly integrates with Marel s intelligent production control software Innova. Innova allows for easy-to-use remote programming, control, real-time monitoring and reporting on actual performance. Information about all pieces and portions is collected in real-time and stored in the Innova database, enabling users to analyze and optimize their portioning process. 11

12 CAS SmoothFlow breakthrough in South America First controlled atmosphere stunning systems in Chile and Brazil. The Stork CAS SmoothFlow stunning solution has made its breakthrough in South America, as various important poultry processors in Chile and Brazil have recently opted for this modern and advanced method of controlled atmosphere stunning. In their search for a more animal friendly stunning method which ensures the highest meat quality, Latin American processors are now switching over to Marel Poultry s CAS solution, thereby securing their exports to the EU. What is CAS SmoothFlow? The multiphase Stork CAS SmoothFlow technology complies with the most stringent legislations in the world, including those of the USDA and the European Union. It ensures the highest level of animal welfare and paves the way for top quality breast meat with no blood spots. The fully automated system is available for a wide range of breeds, weights and capacities. The phases of the CAS SmoothFlow process have been sharply defined and arranged to properly control the stunning with an easily and precisely programmable atmosphere. The air mixture near the broilers is continuously monitored and can be adjusted if needed via the touchscreen. In this way, the process can be programmed to a level of accuracy unequalled by other poultry stunners. The Stork CAS SmoothFlow stunning solution is the result of almost 20 years of Controlled Atmosphere Stunning practice and experience. Since its introduction it has been installed throughout Europe, USA and Australia. Now South America is following too. For Marel Poultry it s yet another milestone to be the very first company to install controlled atmosphere stunning systems in Latin America, says Lambert Rutten, Marel Poultry Sales Manager in South America. Chile Agrosuper is known as an outstanding producer in Chile and is the first ever broiler processing company in Latin America to replace electrical stunning with controlled atmosphere stunning. This was a logical step, as the company s San Vicente plant is geared up for exports, including to Europe. EU regulations require processors outside the EU exporting meat to the EU to comply with similar standards to those in Europe itself. Long-term Marel Poultry partner Agrosuper has made a well-considered choice in opting specifically for the Stork CAS SmoothFlow controlled atmosphere stunning, together with the GP live bird handling solution. The whole system in the San Vicente plant, located 150 km (93 m) south of Santiago, consists of two complete lines for 12,000 bph (200 bpm) to replace existing crate handling and electrical stunning systems. Brazil Brazilian poultry processors now also recognize Controlled Atmosphere Stunning as the ideal solution for combining high animal welfare standards with the finest meat quality. As leading poultry processing companies in Brazil also export their products to the EU, it was only a matter of time before the first company would switch to CAS stunning. Lambert Rutten says, CAS is an excellent way of stunning broilers with the lowest risk of bruises. In the end, processors all over the world, and in Latin America too, like to benefit from less need for trimming and more yield. As of now, more and more Brazilian broilers will be CAS stunned and of course much improved animal welfare is also a big plus. marel.com/smoothflow The robust construction of the Stork CAS SmoothFlow concept works with a single straight-ahead belt without any transitions, making for a smoother and more welfare-friendly process. Broilers are not stressed when entering the system because, in the induction phase, they lapse gently into unconsciousness thanks to an air mixture to which extremely precise levels of carbon dioxide as well as oxygen have been added. In the next phase, the stunning effect is intensified using a higher concentration of CO2, which results in an irreversible stun. Visual inspection is possible through windows throughout the stunning process. Consumption of CO2 and O2 is limited, as the air used is recirculated. Manual shackling after stunning is much easier, as operators don t have to hang live, moving broilers. Not only is this an ergonomic benefit, it also prevents injuries to the birds. All of these factors contribute to the best possible end product quality. 12