How To Run A Poultry Processing Plant

Transcription

1 NOVEMBER 2014 Breakthrough greenfield boosts industrial processing in India >3 Premium quality assessment before chilling >4 Customer cases from all over the world From plan to production in eight months > 8

2 CONTENTS Innovation through partnership High capacity Greenfield plant boosts industrial poultry processing in India IRIS move up Multihead Weigher Marel Stork offers a solution, not just machinery Innovation through partnership With commitment to the process, the products and the customer, our people have their processing hearts in the right place. 7 CP Food group chooses Marel Stork for secondary processing technology Agrosuper starts up Lo Miranda plant INNOVA QC: Paperless quality control in real time Nichols Poultry wins We processing photo contest Marel Stork supports markets in Africa Successful large broiler processing at 8 in the US New: SmartLine Grader A revolution in hygienic grading New: MCheck 2 Checkweigher Fast, accurate and reliable checkweighing Sustainability: a key business driver Poultry processing and motor rally: Passion, determination and teamwork Reykjagarður boosts production with StreamLine and TSM Profiler Recent months have seen the launch of yet more innovative new Marel Stork solutions. Visitors to VIV Europe commented positively on our new products and on the ongoing upgrades of existing solutions. This makes us happy as it tells us that in continuing to invest in innovation we have made the right choice. Our slogan at VIV, We love processing, captures the passion behind our market-focused innovation, part of our DNA. With commitment to the process, the products and the customer, our people have their processing hearts in the right place, listening to customers every day, learning from them, translating their needs into successful new developments, helping them achieve their objectives ever more effectively. A welcome example is our new IRIS EV quality assessment system for the evisceration process. The quality grade of each product can now be determined before pre-chilling, giving processors more time for an optimum match between production and customer orders to maximize profit per product. Furthermore our completely new solutions for stunning, CAS SmoothFlow and the Water Bath Stunner PureSine, have been enthusiastically embraced by the market. Experience in different plants has confirmed them as the new benchmark for responsible stunning, enabling the production of top quality end products. Another well received solution is our 8 Big Bird evisceration line, the Marel Stork answer to the trend towards heavier broilers. The solution launched in the USA at the beginning of the year is already a huge success. With today s challenges and developments the difference is often in the detail, examples being the improved MCheck 2 Checkweigher and the new SmartLine grader. Both have been completely updated with the accent very much on hygiene. Both efficiency and product quality benefit from the updates, particularly when combined with Innova control software. Having a complete range of innovative products is, however, not enough if we want to be our customers best technology partners. A professional sales process, including expert advice, enabling our customers to make the best choices for taking their business forward, but also professional project management and a worldwide service organization: these are other important reasons given by many customers for choosing Marel Stork. Recent months have seen an increasing number of companies opt for Marel Stork Poultry Processing, with many new customers from different parts of the world. While our customers in Europe, Latin America, Russia and the USA continue to invest, ever more equipment is going to existing and new customers in China, Indonesia, the Middle East and Central and West Africa. We are proud to tell you about some of these in this INSIGHT. It just remains for me to remind you of the coming IPPE show in Atlanta US (27-29 January) and VIV Asia (11-13 March) in Bangkok Thailand, where in true Marel Stork style, we will let you experience the various new solutions for yourselves. The shows will lift the curtain on a new year full of challenges, opportunities and developments. I wish you a good read and look forward to meeting you personally at one of our events. Arie Tulp, Sales and Marketing Director Marel Stork Poultry Processing 2

3 Customer Insight High capacity Greenfield plant boosts industrial poultry processing in India Sneha Fresh Chicken and Marel Stork team up In Hyderabad (capital of Telangana, India), Sneha Fresh Chicken and Marel Stork Poultry Processing will build a highly automated broiler processing plant with an initial capacity of 6,000 broilers per hour (100 bpm). The plant will be expandable to a capacity of 12,000 broilers per hour (200 bpm) and incorporates the latest state-of-the art Marel Stork Poultry Processing technology. Sneha is well prepared to grow along with the fast developing Indian poultry processing market. Sneha Fresh Chicken will provide the Hyderabad region with a wide selection of high quality fresh and frozen poultry products, whole broilers, various cuts and filet products. The products meet the highest international standards and will mainly find their way to demanding consumers in hotels, restaurants and quick service outlets in and around Hyderabad. Top quality automated evisceration and giblet processing The Greenfield project incorporates various solutions for high speed automatic evisceration and giblet processing and includes the first Stork VO-20 RS opening machine, the first Stork Nuova 24 evisceration system and the first system for automated feet processing for India. Top quality, automated grading Quality grading is also automated with a combination of the newest IRIS and SmartWeigher. The Stork IRIS vision system incorporates the very latest in image capture and data processing techniques. It will be used to grade both the whole product and its anatomic portions. This helps avoid incorrect grading and costly unnecessary downgrades. The well-regarded and virtually maintenance-free SmartWeigher weighs whole products very accurately, even at the highest possible processing speeds. Every product is put into its most profitable form. Fully flexible, automated cut-up and deboning Changes in the Indian poultry processing market have also made room for a fully flexible, automated cut-up and deboning solution. With the ACM-NT cut-up system and the AMF-BX FlexControl breast deboning system from Marel Stork, Sneha Fresh Chicken will produce a large variety of top quality products. The company can be highly flexible and anticipate pro-actively anticipate customer demands and changing trends. Production will be monitored and controlled overall via the modular PDS-NT Management Control software. More about Sneha Fresh Chicken In India the Sneha Group is a well-known company. It is a large agricultural integration owned by the Reddy family and already known for its feed and poultry production operations. The Company will now start processing broilers right in the middle of one of India s many metropolitan markets, Hyderabad. The region is known for its technology sector and like many regions in India is undergoing rapid change. In India, the wet market still represents around 95 % of all poultry production. The new processing plant will, when fully operational, give a large boost to local and regional industrial poultry processing capacity. Sneha Fresh Chicken and Marel Stork are teaming up for a great future. snehagroup.co FRESH CHICKEN From left to right: Prabhudhan Reddy General Manager, Sales, Erik Talens Area Sales Manager Marel Stork, D. Ram Reddy Managing Director, owner, D. Varun Reddy Director, son of D. Ram Reddy. 3

4 IRIS moves up Until recently the computercontrolled vision system for assessing product quality (Stork IRIS) would usually have been found in the pre-selection line immediately after chilling. The NEW Stork IRIS system 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 thousands 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 tunnel installed in a processing plant handling 13,500 broilers per hour (225 bpm) 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 profitable form and customer orders met as efficiently as possible. The system will also allow effective remedial action to be taken if the quality profile of a given flock is different to expectations. Better product presentation for more accurate grading Each product locates into a positioning wheel driven by the overhead conveyor. This wheel pushes it outwards and ensures that its wings are perfectly presented with no risk of contact with its neighbor. Products are kept strictly separate, allowing both the whole product and its individual parts to be assessed with greater accuracy. Leg grading is better too as these are more visible to the IRIS system in a Marel Stork Poultry Processing evisceration line shackle. More accurate grading means fewer misgrades, less rework, less lost yield and more profit. Grades both wet and dry product equally well Moving IRIS forward from the pre-selection line to the evisceration line has been made possible by the new system s LED lighting and state-of-the-art recognition software. The system, which can assess both the front and the rear of IRIS keeps an eye on every product. Plant yields and profitability can only benefit. Premium quality assessment before chilling: more time to optimize your planning 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, fecal 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 downgraded. Plants producing segmented wings discard wing tips. In such cases downgrading the whole wing creates unnecessary rework. 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. Ultra-reliable Stork PDS-NT XL software keeps track of each product and its quality profile as it moves through the chill or maturation chill tunnel. The system even drops whole products selectively directly from the chilling line, based on this data. 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 color 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 efficiently and react quickly and effectively to changing circumstances. marel.com/iris 4

5 Customer Insight Multihead Weigher at 2 Sisters Storteboom Zeewolde: plug and play Last spring, 2 Sisters Storteboom installed a Multihead Weigher with twenty 3.5 l heads in order to keep up with growing demand for a range of different retail products. 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 project 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 largest 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 giveaway and, indirectly, also production time and labor 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 everything 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 products 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. storteboom.nl 5

6 Customer Insight Marel Stork offers a solution, not just machinery In 50 years UVE, S.A. has grown from a small company founded by a group of veterinarians, into a completely vertically integrated group of companies. With a turnover of around 300 million in 2013 it is the second largest poultry processor in Spain. In Tudela (Spain), home to UVE, S.A. s headquarters and its most modern production location, some 1,300 people will this year produce around 127,000 tons of high quality poultry products. The Tudela plant (2008) is completely equipped with Marel Stork Poultry Processing equipment, from live bird handling, CAS Multiphase stunning, evisceration and automatic giblet processing, air chilling to cut-up and automatic deboning. It produces a wide variety of fresh and frozen poultry products: whole broilers, a wide variety of parts, bone-in and deboned breast fillet products, carcasses, giblets, as well as patties, sausages, meat balls etc. As UVE, S.A. s slogan says, there are a thousand ways to eat healthily, referring to UVE, S.A. s mission of providing consumers with versatile, healthy, safe and tasty poultry products. satisfying our customers customers, in taking care of our animals, the environment, and in being a good employer. To make all that happen we also need a leading provider, a leader in technology. Marel Stork is that leader. If we have a challenge, we get a solution, not just a machine. We look for interaction, for partnership. Personal approach is the magic factor The relation between Marel Stork and UVE, S.A. has been growing over the last few years. UVE, S.A. has contact with Marel Stork in Boxmeer (the Netherlands) and with the local office in Spain. To us the local Spanish office is of great value. The people there speak our language, understand the local market needs perfectly and know our plant. They do not just sell spare parts, they solve problems. We know that when a maintenance engineer or specialist is needed we can count on them. Our relationship is good. The very personal approach is the magic factor in the relationship with Marel Stork. Consumers enable us to grow, to improve Last spring, a delegation from UVE, S.A. visited VIV Europe and a reference plant. The goal was to get to know the latest developments in technology. At VIV Europe, Marel Stork presented over ten innovative solutions. It is good that we could experience the latest developments live and discuss their added value. It helps us to get ideas of what is possible now and what could be possible in the future. We must understand that through our products we are part of the daily lives of many people. This is a big responsibility we share. The consumers enable us to grow, to improve. Marel Stork is the leader in technology. If we have a challenge, we get a solution, not just a machine. We look for interaction, for partnership. Pedro Sieso Director of the UVE, S.A. Tudela plant. We stay ahead with the best technology UVE, S.A. believes that the production of high quality products requires efficient and effective processes and equipment. Pedro Sieso, Director of the Tudela plant, says, We have chosen innovative processing equipment, the very best technology. It enables us to produce the best products in the best possible way. We look for fast answers, because developments and consumer preferences change faster these days. People want to spend less time on cooking. The traditional consumer role has changed. We support this new environment with new safe and sustainable products, new innovative packing and different presentation methods. We adapt to a changing society and must provide solutions for these needs, always stay one step ahead, together with our clients and providers. Leader in technology UVE, S.A. knows how to produce good and safe products. The Company controls the whole production chain: We buy cereals to produce feed for our animals, which we raise ourselves, looking after their welfare. We transfer them into poultry products that we sell via different channels: retailers, supermarkets, wholesale and catering companies, in Spain and abroad. We want to be market leader in many areas: in making safe, high quality, attractive and affordable poultry products, in controlling our process, in From left to right: Alberto Ibarra Production Manager of the UVE, S.A. Tudela plant, Pedro Sieso Director of the UVE, S.A. Tudela plant, Harm ter Heerdt Area Sales Manager Marel Stork, D. Antonio Sánchez Sánchez President of the UVE, S.A. group, Mark Gerritsen General & Service Manager, Marel South Europe, Nacho Burgaleta Maintenance Manager of the UVE, S.A. Tudela plant. 6

7 Customer Insight CP Food group chooses Marel Stork for The day after VIV the UVE, S.A. delegation visited Esbro (Wehl, the Netherlands). The 13,500 bph (225 bpm) plant houses many of Marel Stork s innovative solutions. They commented that the visit to the reference plant was great, very interesting: It proves in practice how lines run. The warm reception and lively discussion were great. We are committed to good results. This high speed solution we saw gave us inspiration for the future. secondary processing technology This year UVE, S.A. celebrated its 50 th anniversary in Tudela, home to the Company s headquarters. In the company of many guests, UVE, S.A. looked back over its heritage of five decades of successful growth. The building of a new hatchery in Tudela has been announced. This latest investment will contribute towards the next phase in UVE, S.A. s successful growth. Marel Stork is grateful to be able to support that growth. uvesa.es Beijing Dafa Chia Tai Co.,Ltd. (Part of the CP Food Group) and Marel Stork Poultry Processing signed an agreement for Marel Stork to supply a highly automated secondary processing solution to one of the Company s high capacity poultry processing plants in China. The project includes equipment for automated cut-up, automated deboning and production control software, enabling full traceability. Dafa Chia Tai s choice for Marel Stork is a conscious choice for high end quality in all aspects. It is in line with Dafa Chia Tai s strategy to provide consumers with only the very highest quality, safe poultry products. The CP Food Group is one of the world s largest food producers and a leading agricultural company in China with factories nationwide. The group is completely vertically integrated and has a farm-to-table strategy. Bio-security and food safety are paramount to their production methods. The group aims to become the kitchen for the world and a source of energy for human beings, emphasizing environmental protection, developing healthy food and guaranteeing consumer safety. Traceability supports food safety The Beijing Dafa Chia Tai project (Beijing, China) includes a new Marel Stork scalding system and various A-frame pluckers, laying down a perfect foundation for the downstream process and resulting in a higher paw quality. Paws are valuable products in China. After chilling and automatic grading, a selection line incorporating the recently introduced Smart Weigher, the most accurate inline weighing solution, and PDS-NT software determines the optimum destination for every product. All data are stored to give full traceability, thereby allowing the Company to adopt policies which ensure the highest food safety standards. After quality selection, the modular flexible ACM-NT automatic cut-up system produces a wide selection of high yield cuts. The ACM NT system includes the well-known JLR Anatomic leg module, the industry reference for producing high yield anatomic legs. Top quality breast deboning Breast caps cut on the versatile ACM-NT are deboned with the help of two AMF-BX FlexControl systems. Using less labor than any competitive set-up, the two systems produce a wide variety of top class, high yield fillet products with lower trimming losses at an average capacity of 7,200 breast caps per hour. The menu controlled AMF-BX FlexControl allows settings to be changed automatically when breast cap sizes change, optimizing processing yields and making the job easier for people working with the system. Local presence Automation of secondary processing in the Beijing Dafa Chia Tai project using the latest Marel Stork processing technology is a good example of the direction in which poultry processing in China is headed. Marel Stork is proud to support this development. The company s presence in China, which includes the local production of equipment and a locally based team of engineers, is proof of its long-term commitment to this important market. bjdafa.com 7

8 Customer Insight Agrosuper starts up From plan to production in eight months As the youngest of 10 children, Mr. Gonzalo Vial started his business in 1955 selling fresh eggs. Five years later he expanded into poultry meat sales, but it was not until 1974 when he created the Super Pollo brand. Over the years, the company Agrosuper, became ever more professional, diversified and grew strongly, and for more than 15 years Marel Stork Poultry Processing has been providing processing technology and support. Now, and after experiencing a devastating fire in December 2013, the broiler processing plant in Lo Miranda was started back up after 8 months of reconstruction. Agrosuper took a harsh blow during Christmas 2013: a fire caused great damage to the processing plant in Lo Miranda. The day after, a team from the company, among them Marel Stork Area Sales Manager, Lambert Rutten, met to assess the damage. It was clear that the whole plant had to be rebuilt. Agrosuper responded fast. The San Vicente plant, located about 50 kilometers further south, scaled up to receive the Lo Miranda operators. The commitment and flexibility of all colleagues safeguarded production and labour. Challenging deadlines After four weeks of work a team of specialists from Agrosuper, Poch and Marel Stork presented a complete reconstruction plan for the new greenfield poultry processing plant, which was confirmed shortly after with the signing of the contract. To this end, and during the meeting, Andrés Prado Noguera, Manager of Industrial Processes and Projects, Agrosuper, stated that I know that our 1st September deadline is very challenging. We are in this as one team. Together we will make this happen. At the end of January the terrain in Lo Miranda was prepared for construction, and on 1st September 2014 the first broilers were processed. The plant The brand new high-speed broiler processing plant includes the first GP Live Bird system in Chile, with a new Water Bath Stunner and Killer K15, preventing incidents during the primary process. Lo Miranda also has Nuova automatic evisceration and giblet processing to give first-class evisceration results and the highest quality giblets. Product passes through an air chilling tunnel and an IRIS system takes care of the automatic quality grading of whole birds and their anatomic parts. The selection and cut-up departments put every product in its most profitable form. The flexible Stork ACM-NT cut-up system produces all the usual cuts. The system is installed on a mezzanine floor, which gives a smooth product flow at ground level. At this moment deboning is still being carried out manually. The layout and process flow have, however, already been prepared for the installation of a series of AMF-BX breast cap deboning systems, which have already been used at its San Vicente plant for many years now. Trends in Chile For many years the whole broiler was by far the favourite way to eat chicken in a traditional Chilean family. Today, Chile has a large young, urban population, a strong middle class, smaller families, which spend less time in the kitchen. Convenience food and single-person portions are very popular. Supermarkets offer all possible poultry products, both fresh and frozen, marinated, coated, or natural, as well as other alternatives. Furthermore, new products are constantly being developed because consumers preferences are changing faster than ever. As is the case in many countries, poultry meat is considered a versatile product, a healthy choice, given that health has become a strong driver. So much so that the Chilean government encourages more sustainable production methods and healthier eating. With a consumption of 37.5 kg of poultry meat per capita, 8

9 Lo Miranda plant Signing the agreement for the Lo Miranda plant From left to right: Miguel Sánchez Carril General Manager of Poch y Asociados S.A., Andres Prado Noguera Manager of Industrial Processes and Projects Agrosuper S.A., Alejandro Montes Ortuzar Manager Acquisitions of Agrosuper S.A. and Lambert Rutten Area Sales Manager Marel Stork. poultry products are becoming more popular than beef, a traditional classic. Agrosuper Agrosuper produces broiler meat, turkey, pork, salmon, and processed products, all of which are manufactured to the highest quality and food safety standards. All Agrosuper brands are available in every retail market in Chile. The most popular are Super Pollo (chicken products), Sopraval (turkey products), Super Cerdo (pork products), Super Salmon (salmon products) and La Crianza (pre-prepared products). Agrosuper s export business model is aimed at niche markets with local products through brands developed by the company. This approach has identified opportunities abroad allowing the Company to adapt more easily to new markets, different types of customer and new ways of consuming its products. While exports have been increasing, the strategy has been based on opening offices in the main markets: Italy (2002), United States (2003), Japan (2004), Mexico (2005), China (2005 and 2012), and Brazil (2012). Main export markets have been the USA, Mexico, the UK, Puerto Rico and China. In 2013 these accounted for 67% of exports of broiler products. The main products were breast filets and wings, mainly exported to the United States, Mexico and the European Union, paws to the Chinese market and hearts to Brazil. Environment Environmental management is a pillar of strategic development for Agrosuper, and is based on searching for and implementing new technologies, efficiently using natural resources throughout the production chain and minimising the outsourcing of animal production. For more than a decade, Agrosuper has been committed to sustainable development by reducing CO2 emissions in its production process. To this end, and in line with the Kyoto Protocol, Agrosuper became the first agroindustrial company to issue carbon credits, therefore reducing its greenhouse gas emissions by more than 8 million tons. Community focus Since the beginning, Agrosuper has been linked to its neighbouring communities, generating work spaces and creating bonds of trust, promoting sustainable development, through the We re Neighbours work programme. To this end, at Lo Miranda where Agrosuper was born the work carried out can be seen, both in production and community relations. This is where the poultry processing plant was damaged by fire in December 2013, and where now, with the support of the local population and authorities, poultry products are processed again. Solid relationships lead to success And with this set up, Ricardo Gomez Errazuriz, Lo Miranda Processing Plant Manager said to the Marel Stork installation crew on site: We did a great job together. If you see what has been done in only eight months, it s quite an achievement! We had to struggle to get the project ready in time, but Lo Miranda was commissioned in time, just as agreed. The quick work is proof of the excellent relationship between Agrosuper, Poch and Marel Stork, but it is, above all, proof of Agrosuper s constant drive to succeed and constant drive to succeed and keep on moving forwards. Marel Stork is proud to be Agrosuper s technology partner in poultry processing. agrosuper.cl 9

10 INNOVA QC: Paperless quality control in real time Nichols Poultry wins We processing photo contest Poultry processors require solutions that meet the needs of a demanding environment and short delivery times. The way data is handled is critical to the constant improvement of processes. Innova Quality Control helps you meet these demands by enabling you to catch potential problems early, react in real time, continuously improve product quality, increase food safety and minimize rework. Innova Quality Control enables paperless control and automation of the quality control process throughout the whole value chain. Quality control managers can collect important, valuable information for custom-made reports and trend analysis. Efficiency levels can be raised by using dashboards to monitor performance and respond in real time, explains Gústaf Helgi Hjálmarsson, Innova QC Sales Consultant. This enables processors to benchmark suppliers, and helps avoid potential problems by building on past trends. Innova QC allows for flexible registration, reliable data collection and full traceability. All inspections are directly linked to production, from live bird handling up to the final products. Full traceability is essential for satisfying regulatory obligations and consumer confidence. With Innova, traceability is an integrated part of your systems. Real time control enables immediate action Keeping processing times to a minimum is crucial. If there is a quality deviation, you must know in real time what happens. This enables you to respond quickly, prevent possible risk and minimize costly disruptions. Moving from paper to paperless quality control, using Innova QC, is a perfect way of doing this. Online and Offline Quality Control Many plants can t rely on stable internet connections, so Innova Quality Control has built-in offline features to enable control regardless of Wi-Fi signal. This is a valuable feature when it comes to environmental control, hygienic control and supplier audits, to name but a few. Innova QC supports international food safety standards and all types of quality management systems, big and small. The system s ability to work off-line is especially useful for the poultry industry when it comes to the collection of live broilers, where quality control can start at the farm. Innova QC supports the use of cameras, enabling inspections to take place using a tablet with built-in camera and supported by an inspection list with pictures. Proven success Over 1,000 Innova Software Solutions systems have been sold, including about 150 Innova QC systems, with nearly 500 QC stations. Innova Quality Control is a mature system that has been developed in cooperation with some of the world s major food production companies. marel.com/innova Last spring, as part of the launch of our We processing campaign, we held a photo contest. Customers and friends in the poultry processing industry were challenged to take a picture of the We processing sticker. Nichols Poultry in La Trobe (Tasmania, Australia) won first prize with their contribution. The picture shows the sticker We processing brought to great heights on the Nichols wind turbine. The company s turbine helps to reduce the carbon footprint of this Tasmanian poultry processor. Like Marel Stork Poultry Processing, Nichols Poultry has a passion for poultry processing! Anton de Weerd, Managing Director of Marel Stork, says, We connect to poultry processing, connect to our friends and customers, and we do it with our heart. We processing expresses our passion for poultry processing which we share with the poultry processing industry. We, Marel Stork, are a group of enthusiastic, passionate people developing processing solutions with respect for animal welfare, our world and always with the success of our customers and the health of the consumer in mind. You can easily say that being innovative, being passionate about processing, is part of our DNA. With We processing we want to send a smile to the industry, we radiate passion and are confident about the future. We processing on social media The latest Marel Stork campaign was launched this spring, prior to the VIV Europe tradeshow. Rob Nichols, Managing Director Nichols Poultry (left) gets the ipad mini from Marel Stork Area Sales Manager Dirk den Hartog. Some examples of pictures can be seen on: twitter.com/storkpoultry or facebook. com/storkpoultryprocessing nicholspoultry.com.au SPP_VIV_EU_STICKERS_297WIDE_210WIDE_14_LC.indd :44:59 10

11 Customer Insight Marel Stork supports markets in Africa Mr. John Sangwa, owner of the Mattaniah poultry processing plant in Zambia (right) and Marel Stork Areas Sales Manager Ruud Berkers. Ruud Berkers Area Sales Manager Marel Stork (second from left) visits a customer in Nigeria with local representatives Charles Aladewolu (second from the right) and Joseph Osinibu (right) from the Teco Group. For more than three decades, Marel Stork Poultry Processing has been supporting poultry processors in many African countries, from Tunisia and Sudan right down to South Africa. Many successful projects have been executed, offering solutions for companies starting processing on an industrial scale for the first time, right through to solutions for companies producing large volumes of poultry products with the help of highly automated systems. Growing market More recently, various markets in West, Central and East Africa are moving from traditional wet markets to a more industrial way of processing poultry. Reasons for the growth in these emerging markets can be found in a growing, young population and ongoing urbanization. There is a stronger middle class with less time and more money to spend. Consumers are more demanding and look for safe food. Retail chains (like Shoprite) are gaining ground. Several international QSRs (such as KFC and Mc. Donald s) are present. These companies look for high quality, stable production. Food safety, production yields, and product diversity are becoming more important. Besides whole products, various fresh and frozen parts are becoming more popular, especially for supply to caterers and restaurants. Governments encourage local industrial production thereby creating jobs, stimulating the local economy and offering an affordable source of high quality proteins. The infrastructure improves and cold chains become more effective. Higher profitability Marel Stork has successfully installed several processing plants in these emerging markets, with the emphasis on the automation of primary processing. The automation of scalding and plucking, combined with semi-automatic evisceration and controlled chilling, enables a higher level of production, greater production efficiency, a consistent and manageable process, safe, high value end products and high yields. Poultry processors become more profitable and differentiate themselves from their wet market colleagues. Modular flexibility All Marel Stork equipment is modular. Automated and semi-automated process steps can be combined with manual operations. Later, when production increases, more steps can be automated. To increase capacity, the processing line can be modified and extended without having to invest in a complete new line. More than equipment There is a growing awareness that automation and scaling-up will be required to meet rising demand and changing quality requirements in the years to come. The right selection of durable, high quality equipment, adapted perfectly to local conditions, is the basis for successful processing. But in addition to the right equipment, many customers are looking for knowledge, advice and support. Marel Stork Area Sales Manager Ruud Berkers says: Everyone knows that we have extensive knowledge and experience of developing along with a local growth market. We always respond to the unique local situation and offer customized solutions that fit a specific market. Our advice and support before, during and after installation, is the real added value to our customers. Good and reliable service is of key importance. I m convinced that our solutions support poultry processors in the best possible way. Our technology has proved this historically, proves it today and will continue to prove it in the future. Cooperating enthusiastically with our customers, we will be able to realize many more successful projects. Some recent projects Gambia, Empas Poultry, Greenfield 1,000 bph. Ghana, Aglow Farms, Greenfield 1,000 bph. Nigeria, Zartech, 4,000 bph. Nigeria, Sayed Farms, Greenfield 2,000 bph. Zambia, Mattaniah, Greenfield 2,000 bph. 11

12 Customer Insight Successful large broiler processing at 8 in the US Case Farms in Dudley (North Carolina, USA) had a simple goal: to process large broilers at higher speeds than they were able to achieve on 6-inch center shackles without experiencing any loss in yield or reduction in quality. The solution they chose was a complete Marel Stork Poultry Processing evisceration line from rehanger through final washer, newly developed on an 8-inch center shackle: the Nuova 8, including a complete, automatic giblet harvesting solution. After nine months of operation, the results of their decision were in. We have been able to get a better yield at higher speeds, Plant Manager Brian Hanna said. The line has surpassed our expectations. Of particular attention to the team at Case was the ability to harvest high quality giblet packs or pluck as they refer it. The main reason we chose Marel Stork equipment was the capability Stork has to harvest pluck, Brian explained. They have been very pleased with the quality and yields that they have achieved with the Nuova 8 system: One of our customers says we send the best pluck of any of their suppliers, Hanna noted. Zero chain stretch with Automatic Tension Control Every nine months to a year, Case Farms was used to having to change their chain out because of chain stretch. With the addition of ATC (Automatic Tension Control) system in their new 8-inch line, they have been able to eliminate chain stretch. Here we are after seven months of operation and we have had zero chain stretch, David Gammon, Maintenance Manager, noted. Reduced chain stretch reduces their cost of operations by eliminating the need to bring in people at the weekend to change chain out and it allows them to keep their timing intact, reducing the need for adjustments. I love the Opening machine Another favorite piece of equipment is the opening machine (the Stork VO-20 Reference Series). The opener, in my opinion, is the best piece of equipment on the market, Hanna said. It blows the others away. I love that machine. The Opening machine VO-20 RS prevents damage to the intestines and does not bare the tip of the breast bone. The length of the opening cut can be adjusted quickly and easily during production allowing a precise opening cut to be made irrespective of product weight. Increased yields, more efficiency Gammon said they have seen no gall staining and no machine damage which has helped them with yield. Case Farms has actually been able to reduce labor while increasing yields. The line has definitely helped us with yield which means more profit. We are more efficient, Gammon explained. And we are achieving a better quality of product birds or pluck. Case Farm has been able to increase their birds per man hour in the front end of the plant by 30 per man hour. They are now running at 100% line efficiency six days per week. 98% efficiency is bad for us, Hanna laughed. Innovation through partnership Case was the first installation of the Nuova 8 system and Hanna admits that created a few challenges. Marel Stork was with us during the entire time to be sure we solved any problems, he noted. Marel Stork learned with us. We did make the right choice, Hanna said. For what we do here these are the right pieces of equipment. The line is the perfect fit for us. casefarms.com IPPE 2015: Innovation through partnership International Production and Processing Expo (IPPE) Expanding your big bird processing capabilities Join us at IPPE 2015, booth 4423/4431, January 27-29, 2015, Atlanta, Georgia US Check marel.com/poultry-events 12

13 New: SmartLine Grader A revolution in hygienic grading New: MCheck 2 Checkweigher Fast, accurate and reliable checkweighing The new SmartLine graders offer the speed and accuracy of previous generations of Marel graders combined with greatly enhanced hygiene and serviceability. SmartLine has an IP69K rating providing the highest level of protection available against high temperatures, ingress of dust and high pressure water. The new MCheck2 Checkweigher, launched this summer, combines high levels of accuracy with flexibility and high capacity. The machine is approved for processing as well as for end of line applications, making it the ideal choice for any poultry processing company. Its open frame design and minimal use of horizontal surfaces ensure maximum hygiene during high-pressure washdown. Furthermore, strip-down time for cleaning has been vastly reduced, resulting in minimal downtime. As well as being super-hygienic, the SmartLine is fast and highly accurate. Maximum throughput is 250 pcs/min, depending on the size of platform. With its complete modular design, the SmartLine can be configured to meet every processor s needs. In-depth reporting: Innova Grading The SmartLine features a comprehensive, real-time reporting function (Innova Grading) that gives the operator a complete overview of the production process. Real-time data generates reports on weight distribution, average weights, a packing overview and packing list, as well as the standard overview and lists. This data can be viewed via dashboards. Based on the valuable KPIs provided by Innova Grading, you can optimize your grading and batching results. Decades of reliability Marel Stork Poultry Processing has been supplying graders for more than 30 years and sources only the most reliable parts and components. Using few loose parts reduces the risk of damage and raw product contamination. Marel Stork graders are renowned for their robust construction. Even under the harshest conditions, the average lifetime of our Main Benefits: Unique hygienic design Full wash-down to IP69K Speed and accuracy combined Flexible grading and batching Includes Innova Grading graders is 15 to 20 years. All this ensures low cost of ownership and reduced downtime. Marel Stork is excited to be launching the new SmartLine Grader series and offering its customers a revolution in hygienic grading, along with the combination of speed and accuracy, and the flexibility in grading and batching that meet the needs of every poultry processor. marel.com/poultry-smartline The checkweigher monitors and optimizes the accuracy of your processing equipment, and ensures compliance with weight legislation across a wide range of products. It features a range of metal detection and reject options which remove off weight and metal contaminated products from the product flow to ensure food safety and quality control. Innova Checkweighing software MCheck 2 Checkweigher incorporates Innova s Checkweighing module which provides real-time monitoring of key performance indicators and the collection of data for statistical analysis, enabling you to track operational performance and optimize production line efficiency. Detailed E -weighing reports are produced to ensure vital compliance with average weight legislation. Full wash down hygiene Thanks to its sturdy design, MCheck 2 Checkweigher can withstand intense wash-down procedures to IP69K, providing the highest protection available against high temperatures, ingress of dust and high pressure water. Quick release belts and swivel reject bins make for easy cleaning. Modular construction enables MCheck 2 Checkweigher to be configured to suit virtually any production requirement, thanks to a choice of weigh cells, infeed conveyors, metal detection and reject options. marel.com/poultry-mcheck2 Main Benefits: Full wash-down to IP69K Approved for process and end of line applications Speeds up to 245 ppm subject to product size Continuous flow dynamic weighing provides accuracy down to 0.5g Includes Innova Checkweighing 13

14 Sustainability: a key business driver Sustainability is a key business driver for Marel Stork Poultry Processing. The Company 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 urbanizing population and from rising living standards and expectations. 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 As people grow more wealthy, their diet changes. They eat more meat, whose production involves large volumes of water. Some 5,500 liters (1,452 gal) are needed to produce a kilogram (2.3 lbs) of beef; 4,900 liters (1,294 gal) are needed to produce a kilogram (2.3 lbs) of pork meat. Poultry meat needs the least. Even so, the figure is still some 3,900 liters (1,030 gal) per kilogram (2.3 lbs). The cost of water, its availability and consumer preference have led to the development of technologies which have driven water usage down. The latest high volume plants in Europe now use less than 10 liters (2.2 gal) per product. Clean with less water Water 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 system where clean water supplied to rinse the containers is re-cycled to the system s main and pre-wash stages. Product is washed at various stages during primary processing. Marel Stork has introduced a technique for improving washing efficiency. This technology mixes air with water and sprays the mixture onto the product at high velocities. Water consumption has been reduced by half with an increased cleaning efficiency. Besides using large amounts of water, washing down equipment after production takes up valuable time. To reduce both, Marel Stork designs equipment which is easy to clean, using sloping surfaces wherever possible and avoiding corners where debris can accumulate. Process with less water Water is an excellent conductor of heat and electricity and has traditionally been used to help stun, scald and chill product. These operations can now be done using either no or significantly less water. Marel Stork Multiphase Controlled Atmosphere Stunning technology uses no water at all and has established itself as a reliable, effective alternative to electrical water bath stunning. It is increasingly popular with high volume broiler processors. Scalding and plucking account for approximately 17% of the water used in a processing plant equipped with a conventional immersion scalding system. Although there has been ongoing improvement, the basic technology has remained largely unchanged for decades. Immersion scalders use large amounts of water. AeroScalder a revolution in scalding Taking a huge step forwards in the science of scalding poultry, Marel Stork launched its revolutionary AeroScalder. The system is now in everyday operation in a number of plants. AeroScalder uses moisturized hot air circulated at high velocities to separate Avoid waste, protect the environment, conserve valuable finite resources key business drivers in Marel Stork s ongoing quest to bring its customers only the very best in responsible processing solutions. 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-line Sustainability 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 PDS-NT / Innova monitoring and control system. Broilers are quality graded and weighed at various points during the primary and secondary processes. The system allocates each individual product automatically to the downstream process 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. Follow Marel Stork on social media stay informed 24/7 facebook.com/storkpoultryprocessing twitter.com/storkpoultry 14

15 Customer Insight Poultry processing and motor rally: In 2015 Sjaak Martens will be taking part in the Dakar again. We wish him good luck! Passion, determination and teamwork Motor rallying and poultry processing have many things in common, at least where Sjaak Martens, Operational Director Processing at 2 Sisters Storteboom, is concerned. Both offer him the chance of blending his commitment and passion for technology and teamwork into a rewarding cocktail. Both are full of challenges and opportunities for enjoying the success of a project well done. It was in the early eighties when Sjaak first got to work with the Marel Stork automatic filleting system. I think it is fair to say that we virtually developed the system together with Marel Stork Poultry Processing, he says referring to the frequent contact he had at that time with Stork development engineers. As the years went by, the system, now known as the AMF-BX FlexControl breast filleting system, grew. Cuts became more precise, new modules were added and yields increased. Today 2 Sisters Storteboom has over 20 systems in everyday use at its Nijkerk plant in the Netherlands, the center of its breast filleting operations. Every detail has its goal Sjaak continues, For me the AMF-BX is both technically and technologically a good reliable system. Like all Stork products it is high quality technology. Marel Stork doesn t just develop something which works very well, the Company also goes for technological solutions which keep their edge longterm. Developments can sometimes take quite a while but you know that once they have been released for sale they were really worth waiting for. Every detail has its goal. Get the most out of it When he was 15, Sjaak s passion for machinery and all things technical led the way to motor cross. His love of nuts and bolts, combined with his relentless drive and energy, have helped him to succeed. Like the AMF-BX, he got to know every millimeter of his bike and, together with his team the most important key factor as Sjaak says they improved every detail. In 2013, Sjaak and his team successfully finished the Dakar, the world s most difficult, most challenging rally. It was very challenging and rewarding. My biggest fight, says Sjaak is to win against myself, to give that little extra, time and time again. Improved details raise profitability In his job as Operational Director Processing, Sjaak also gives that little extra. You need focus and determination. Together with our team and the people from Marel Stork, we go on, we challenge each other. In the filleting business every extra bit of yield counts. It s a game of volumes. The new Marel Stork de-skinning module fits well in this picture. The challenge was to improve the old version, again lift yields and improve the bacteriological aspects of the module. After testing long-term in day to day practice and with changes to some details, the new de-skinner was working very well. Storteboom hosted the tests, at the same time trying a number of alternatives. In the end Storteboom chose the Marel Stork solution. The new improved Marel Stork module takes off the skin very well, especially from breast caps we process after the weekend, says Sjaak. We see higher yields; more breasts are de-skinned correctly. We have less rework and less damage of the fillet. It leads to lower costs and fewer downgrades. Bottom line: a more profitable process. storteboom.nl Sjaak Martens Operational Director Processing Operational Director Processing at 2 Sisters Storteboom (left), Sander de bruin Area Sales Manager Marel Stork. 15

16 Reykjagarður boosts production with StreamLine and TSM Profiler With growing demand in Iceland for deboned products like breast fillets and deboned thigh meat, the need for further improvements to Reykjagarður s became more pressing. A first solution was found in the Poultry StreamLine, a system for maximizing the deboning process. Poultry StreamLine keeps a consistent flow of product in front of the operators. Their performance is monitored and every operator is ranked against a system target. With the help of Innova software processors can get real-time feedback on yield, quality and throughput. It is a compact and extremely flexible solution. Higher yields, higher throughput, higher quality Matthías Hannes Guðmundsson, Director of Reykjagarður, says, For us StreamLine is a cutting edge solution which is performing beyond our expectations. Shortly after installation, we saw higher yields, higher throughput and higher product quality. Data from the system enables us to manage product flow, streamline the process and monitor operator performance. It became easy to provide additional training where needed. After a successful implementation of StreamLine, the time was right for the next improvement project. Superior cutting quality and accuracy Over the last few years Reykjagarður has been seeing a growing demand for breast fillets. Mr. Guðmundsson continues, Our main customers are the high quality food service market and restaurants in Iceland. They are looking for healthy, high quality and versatile product that is consistent in shape, form and weight. Breast fillet provides the perfect base but is rather big for the portions our customers want to sell. We trim the fillet, but we wanted to do this with a minimum of labor and, if possible, with a minimum of trimming losses. The TSM (Template Slicing Machine) Profiler was shown to Reykjagarður and was well received. The TSM Profiler is designed to produce identical portions for the foodservice industry. The machine cuts uniform and natural looking poultry products. Its superior cutting quality and accuracy ensure that fillets are used in the best possible way for the production of value added products. For processors, the TSM Profiler is a single solution for increasing the value of their portion controlled products. More on Reykjagarður Reykjagarður (Reykjavik, Iceland) is a completely vertically integrated company with its focus on the production of a wide variety of fresh, high quality poultry products, mainly for restaurant, catering services and retailers. Besides fresh poultry products, the company also produces a variety of frozen and convenience products such as sausages, cold cuts, chicken burgers, nuggets, cordon bleu, cooked natural and marinated chicken strips, etc. All products and processes are fully traceable throughout the production chain and the Company pays a lot attention to welfare and environmental impact and is launching its Social Responsibility Program on the company website. Over the last 20 years poultry meat consumption in Iceland has quadrupled. Annual consumption per capita is around 26kg (57 lbs), the highest of the Nordic countries. The market offers many opportunities for fresh value-added products. holta.is Global presence Marel Stork Poultry Processing is the leading worldwide supplier of processing systems for broilers, turkeys and ducks. With a strong focus on innovative technologies and service, we provide inline solutions for every processing stage and capacity level. We offer integrated solutions spanning single processes to complete processing plants, including live bird supply, slaughtering, scalding and evisceration, chilling, cut-up and deboning, X-ray bone detection, portioning and slicing, weighing, grading and batching, packing, production control software and preventive maintenance programs. Our products enable our customers to produce a vast range of products while maximizing yields, product quality and value, as well as providing full traceability. Marel Stork Poultry Processing B.V. P.O. Box AC Boxmeer The Netherlands T: F: E: info.poultry@marel.com marel.com/poultry Marel Stork Poultry Processing Inc. P.O. Box 1258 Gainesville GA USA T: F: E: usa.poultry@marel.com marel.com/poultry Stork Poultry Processing is a trade name of Marel Stork Poultry Processing B.V. Copyright Marel Stork Poultry Processing B.V., The Netherlands, 2010: All rights are reserved. Any reproduction or modification of all or part of this publication, regardless of the method of reproduction or modification used and regardless of the carrier used, is strictly prohibited, unless written authorization by Marel Stork Poultry Processing B.V. has been obtained beforehand. Those acting in breach of this notice expose themselves to criminal and civil prosecution, in accordance with the international conventions and copyright laws. The data published herein answer to most recent information at the moment of publishing and are subject to future modifications. Stork Poultry Processing reserves the right to modify the construction and the execution of their products at any time without any obligation on their part to modify any equipment delivered before accordingly. The data mentioned are meant as an indication only. Stork Poultry Processing assumes no responsibility for errors or omissions in the data published or use of the data published. The publication of these data may not be interpreted as a warranty or guarantee of any kind (either expressed or implied). INSIGHT-SPP-Nov14-ENG