Newsletter - BAADER Food Processing Machinery

PNewsletter
o u lt ry
FROM
LINCO
&
BAADER
-
W W W . lincofood . com
www . baader . com
G row wi t h B A A D E R L I N C O
Solution flexibility pays off
In a world of growing populations and a higher amount of people with the possibility of purchasing meat, the demand for animal protein will increase greatly in the
coming decade. According to various forecasts, poultry will be the preferred animal
protein.
In BAADER LINCO we see it as one of our main targets to help our customers
achieve the best possible profitability and efficiency. With this in mind, focus is on
solutions that can be used to grow with the demands in the years to come and to
measure and monitor the processes from live bird to packed product. We help you
to know the incoming product and minimize the giveaway through the subsequent
processes.
At BAADER LINCO we know our customer needs to be flexible and therefore we
design your solution to fit your reality with shifting flock variations and shifting market demands.
I P E Atl anta
Read more inside:
J an u ar y 2 0 1 2
Case: Holambra is growing with BAADER LINCO in Brazil
2-3
ClassifEYE - Better than the
human eye
4-5
Evisceration solution
6
New Eviscerator model 218
7
Cases: Venezuela 8-9
InLine Packing Grader
10-11
FlexPacking System
12-13
Maxiload - Live bird handling system14
Maxiload Down Under
15
Maxiload for turkeys
15
X-ray bone detection
16
Spare Parts
17
First Processing
HFS 2010
18-19
20
Best fit for raw input
The first step is to know your raw material. In order to
find the best fit for the raw input, BAADER LINCO offers
various inline weighing, weigh transfer and vision quality
classification solution. See for yourselves inside the
magazine, how ClassifEYE can help you collect valuable
data for production planning4-5
Venezuela
Poultry processing in Venezuela is growing and BAADER
LINCO is pleased to serve both new and old customers
8-9
Information is power
BAADER LINCO Advanced Processing Solution implies
production management based on real time information
collected automatically or manually on the shop floor.
FlexPacking System and InLine Packing Grader are two new
solutions to optimize the back-end product flow 10-13
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Hola m bra is growing wi t h B A A D E R L I N C O in B ra z il
Raising production, yield and quality
Holambra is currently slaughtering up to
80,000 chickens per day, with a product
mix of 25% whole chicken and 75% cutup. The company employs 600 people
distributed on the slaughterhouse, the
feed mill, the hatchery and the administration. Holambra has also built more
than eighty farms in 10 municipalities of
São Paulo and service providers which
carry rations of live chicken and slaughtered poultry, providing indirect employment to more than 200 people.
Today Holambra is a national reference
in the production of grains, fruits, flowers and especially in the processing of
chicken meat. With revenues exceeding
300 million dollars per year, the company continues to invest in new technologies, new ideas, new equipment and
solutions in industrial automation. Based
on this philosophy, it is possible to increase production implementing modern
processing techniques and to reduce
the final production costs, whilst adding
value to the final product.
The beginning of the partnership
Through this story of success and entrepreneurship Holambra has always
sought new alternatives for improving
processes and new technologies, and in
1992 LINCO Food Systems and Holambra began a great and successful partnership.
‘’That year, LINCO brought one sample
of an ACP-6000 cut-up line to a poultry show in Brazil. It was later offered to
Venzuela on Guyana
Holambra
very favorable terms and
Suriname
we started our friendship
Fr. Guiana and partner-
ma
Columbia
or
Brazil
Peru
Bolivia
Paraguay
Argentina
2
Chile
ship” says Mr. Erico Pozzer, Industrial
Director of the company.
He continues: “after
several
negotiations,
we were convinced that
the best thing to do was
having the automatic
evisceration line and
the automatic cut-up machine in our plant. So, in 1993, we set
up a committee, composed of directors,
managers and advisers to visit the industries and different plants where it was
possible to see this equipment running in
the Netherlands and Denmark.
After evaluating the technology and
costs of each one, we concluded that
The Holambra case:
The Cooperative AgroIndustrial Holambra is located in the city of Holambra,
São Paulo State, Brazil and it is part
of the old Holambra Agricultural Cooperative, founded in 1960, when the first
producers and farmers came from the
Netherlands.
At that time, the production was based
on cultures of rice, corn, soybeans and
flowers, but only some time later they
began to produce chicken meat and
LINCO, by its modernity, robustness and
versatility, would be highly recommended”. This was the beginning of LINCO
equipment in Brazil.
16 years later - still going strong
In 1994, the cut-up and evisceration
lines were installed and after almost 16
years of use they are still running with
low rates of stops and minimum maintenance costs.
Since then, the relationship between LINCO and Holambra has developed and
we stand as major partners.
Due to this project, LINCO gained a
foothold in the Brazilian market as a
benchmark company in machinery and
started the first slaughterhouse with
chicken processing activities in the 70s.
The chicken slaughterhouse has been
running since the 70s and today Holambra has a vertical production chain
with headquarters, farms, hatcheries,
farms integrating breeding and slaughtering of chickens, selling its products
mainly within the São Paulo State.
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Poultry newsletter
equipment for the poultry processing industry.
Many years have passed and today,
almost 20 years later, Holambra has
decided to start studies to renew their
equipment in search of higher yields,
processing power and less use of labour
as these are definitely the major challenges for all entrepreneurs in the chicken industry. This is due to high costs of
labour and huge difficulties in keeping
trained staff inside the slaughterhouse.
Therefore, Holambra has once again
proudly chosen LINCO as its major
partner in order to help them meet these
challenges.
Increasing to 12,000 bph
Today, Holambra’s slaughtering and
processing capacity is up to 8,000 birds
per hour with only one shift. However,
with this new project, bold and visionary, in partnership with LINCO, the
company plans to increase its capacity
to slaughter and process up to 12,000
birds per hour, investing in a completely
new automatic evisceration line including: automatic transfer machine, vent
cutter, opener machine, cropper, neck
breaker, whole birds unloader and specially including our newest Eviscerator
model 218 that separates the internal
giblet package from the carcass. It is
noteworthy that Holambra will be the
first company in Brazil to install the Eviscerator model 218.
Advanced Processing Solution
with increased capacity
BAADER LINCO is increasing capacity
of the APS without compromising the
quality and yield. Holambra in Brazil
is the first place in the world to get the
updated APS solution. We expect a full
release of the updated APS solution in
2012.
computerized system to optimize the efficiency and yield of the cuts. Besides,
Holambra has also invested in a breast
deboning machine, model BA656. This
new equipment is aimed at increasing
the yield and quality of the final product,
since the manual cutting and deboning
will be replaced by automatic lines ensuring greater supply capacity (wings,
legs and chest) and quality for both domestic and export markets.
slaughtering and processing ability,
which could reach 100,000 chickens
per day in one shift, continuing with the
utmost satisfaction with our partnership
with LINCO” says Mr. Erico Pozzer.
In addition, Holambra has invested in a
complete line of automatic cutting, Proflex Compact model, equipped with the
latest technology in by-pass devices and
‘’We are convinced that once again
we have made the right decision to invest with LINCO and also agree on the
choice within our product mix and our
Confirming the credibility and mutual
respect between LINCO and Holambra,
the new investment will definitely contribute to the industry growth and development in Brazil, providing higher quality products and guaranteed customer
satisfaction.
The Poultry team of Holambra
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Poultry newsletter
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A ss u re acc u ra t e and cons t an t q u ali t y m eas u re m en t
ClassifEYE - Better than the human eye
Better than the human eye
The cameras are detecting for following
defects:
Front camera :
- Broken wings
- Skinflaws/Barking
- Bruises
- Feathers
- One Leg Hangers
Back camera :
- Hockburn
- Bruises
- Feathers
- Bile
By introducing the 2nd generation of
ClassifEYE - vision quality classification
system, BAADER LINCO takes advanced
production planning to a higher level.
Valuable information is collected in-line
for downstream use to optimize the following process and for upstream use to
correct flaws in the previous processes.
Knowing the incoming products is the
key to successful production planning.
ClassifEYE can be customized to suit any
production of standard chickens to give
a detailed overview of the quality by
controlling up to 4 cameras (front, back,
left side and right side). When combining this information with weighing data
from an in-line weighing system or a
weigh/transfer unit, the overview of the
incoming products is complete.
Side camera :
- Bruises in wing pits
Visual quality classification using cameras is better than the human eye. The
classification is based on algoritms.
Therefore the classification is uniform and
the performance of the systems constant.
Example from front camera as viewed
in Live Statistic
Downstream operation
The quality information is collected and
transferred automatically to a LINCOflex
module. The products are then distributed to the subsequent processes where
the production manager can choose
what to do with the product based on a
combination of weight and quality using
either a pre-programmed set-up or the
set-up can be edited on the fly.
Software to follow your production
Chicken inspector
This is the live view of
the cameras. It follows
the cameras online
with live statistics on
the screen. It detects
grade A, grade B,
empty shackles and
defects (user defined
grade names) and the
view can be individually adjusted.
Live Statistics - counting the detections
4
for different types of production; define
in details which defects are accepted in
which grade. The changes are made in
a simple and intuitive user interface.
Easy to adjust the grade set-up with a
slider
Grade set-up
Is a grade A always a grade A? In the
grade set-up it is possible to make and
save programs with a descriptive text
Statistics
Overview of the daily production, a
certain time interval (user defined) or
historical data. The statistics can be exported to excel and LINCOflex.
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Upstream correction
An increase in specific injuries indicates that something is wrong upstream.
Through the Live Statistics software incorporated in ClassifEYE this can be
detected even with production running.
Action can be taken inmediately thereby
improving the throughput quality of the
production. The view of the Live Statistics
can be individually adjusted to focus on
the most important details at a specific
moment which makes it possible to:
-Monitor the amount of grade A,
grade B and empty shackles
- Count the types of defects
- Get an overview of incomming product quality and adjust the grades parameters
/
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Simple to operate and easy to
get started
ClassifEYE is a simple effective tool to
streamline the production. It is easy to
install and provides the production managers with real time information which
facilitates production management.
Benefits at a glance
- Better than the human eye
- Know the excact quality of the incoming products for downstream
operation
- Correct flaws upstream
- Small cameras and LED light
- Easy to install and operate
- Easy to clean – hygienic
- Software updates and support online (internet)
Historic data is saved and data can be
tracked afterwards to create statistics on
grades and defects. This means that it
is possible to either correct a problem
when it occurs even with production running or trace it afterwards. Also, data
can be compared.
Poultry newsletter
Founded in 1932 by
the late WP O’Kane,
O’Kane Poultry (owend
by Moy Park since August 2010) is a family
business that strives to offer consumer
value for money, whilst maintaining
the highest standards of product quality and customer care.
The fully integrated group operates
a state of the art processing facility,
feed mill, laboratory and two hatcheries and employs over 2000 people. The Group encompasses both
chicken and turkey production and
produces over 500 different product
lines, ranging from traditional cooked
chickens to more modern ready to eat
convenience products, with emphasis
on higher welfare, free range and organic chickens.
O’Kane Poultry is a major supplier to
both the retail and food service sector supplying branded and own-label
products to blue-chip companies
throughout the UK and Ireland.
Step by step installation of ClassifEYE
We have followed in the footsteps of the engineers implementing the new 2nd generation of ClassifEYE - vision quality
classification at O’Kanes in Northern Ireland.
Step two – Pulling cables
Pulling the cables to the connection box for the Ethernet; each
camera will have its own IP-address at the network.
Facility
The O’Kane Poultry Plant runs 9,300 birds per hour. The
space between the chickens mean that ClassifEYE could be
installed on a straight line. If the space between the birds are
8 inch or lower a 2,5 m nosedip is required. At O’Kane we
installed the full version
with 4 cameras detecting
front, back, left side and
right side.
Step three – Setting up software
Setting up a PC – In an office, a computer with the following
software is installed: Chicken inspector, Grade set-up and
Statistics.
Step one – Mounting
cameras
The cameras are mounted to a beam added to
the existing line above
the chain. It may be necessary to add a small
background.
Step four – Getting started
Running in – the system has to be loaded with material from
the plant and learn to know the grades. It takes about 2
hours to adjust the system to detect the grades and for the
user to get familiar with the software. Afterwards, the programs are easily fine-tuned if needed.
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Poultry newsletter
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Firs t processing : eviscera t ion
High speed evisceration solution
Chickens from picking
Vent Cut, Opener
Evisceration
Cropping, Inside/outside
wash, final inspection
EV chicken for Chilling
Giblet harvesting
(subprocess)
The LINCO Evisceration solution
offers a line speed of up to 12,000
birds per hour with a series of automatic
processing machines performing precise
opening cuts, clean evisceration and
washing of the chickens.
Our focus is to reduce crosscontamination and to deliver the right
quality to the next process. Quality in
all phases and carcass care are our
guiding principals.
Final Inspection/Neck Breaker
6
Cropping Machine
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Firs t processing : eviscera t ion
New High Speed Eviscerator
N E WS !
N E WS !
N E WS !
High speed evisceration
The eviscerated birds are left clean and
the liver quality and the lung removal
are on a very high level after the giblet
packs have been successfully removed
by our patented High Speed Eviscerator
model 218 - up to 12,000 birds per
hour.
A specially formed spoon is modelled
upon the shape of the bird cavity. In a
single action, it picks up the pack for
clean, safe and complete removal. Separated from the chicken, the whole pack
can continue to inspection and giblet
harvesting.
Eviscerator spoon
Transfer of giblet pack
The Eviscerator model 218 makes sure
to separate the giblet pack from the
chicken and transfer the pack for veterinary inspection.
Open design and flexible
With the Eviscerator model 218, LINCO
takes the well known open design and
flexibility to a higher level:
- Easy access for cleaning and maintenance
- Easy handling of large variations in
weight and size in flocks
- Easy to adjust to best performance
based on bird size between flocks
Giblet pack
High quality evisceration
The Eviscerator model 218 delivers the
right quality to the sub-processes by removing the giblet pack in an efficient
and safe way without compromising the
quality of the chicken. The Eviscerator
model 218 offers the following features
at a glance:
-High liver quality
-High lung removal
- Very clean bird after evisceration
- Intact rib cage
- Reduced faecal contamination
Giblets after harvesting
Transfer of giblet pack to further
processing
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Poultry newsletter
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Ma t adero D el C a m po is growing wi t h B A A D E R L I N C O
New Level of Automation
In the city of Cojedes in the Tinaquillo
province we find Matadero Del Campo
C.A, one of the leading poultry
processors in Venezuela. BAADER
LINCO is happy to assist Matadero Del
Campo C.A with the newest investment
which is an upgrade of the entire plant
to run 9,000 birds per hour.
The installation is made in an existing
building and the purpose of the planning
is to reduce downtime. The planning
is done in close cooperation between
Matadero Del Campo C.A and BAADER
LINCO and we expect to reduce the
downtime to an absolute minimum.
After the installation, the plant will be
equipped with all new equipment and
the latest technology from BAADER
LINCO and in addition feature a new
8
level of automation with the ProFlex
Premium Cut-Up System.
The solution features the following new
technologies from BAADER LINCO:
-HFS 2010 Stunner
-
Eviscerator model 218
-
Improved water chillers
-
LINCOFlex Grading System
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N ew P rocessing P lan t f or A li m en t aci ó n B alanceada C . A .
Optimized for Further Processing
Alimentacion Balanceada C. A. called
AliBal is located in the city of Cagua
in the state of Aragua. Aragua is the
6th biggest state in Venezuela when it
comes to population. The main city is
Maracay and close to this, in the valley
of Aragua, we find Cagua.
The AliBal group is one of the
fastest
growing
companies
in
the food industry in Venezuela and
lately they have chosen BAADER LINCO
to supply their new chicken processing
plant running 9,000 birds per hour.
The design of the plant is made in
close cooperation between AliBal and
BAADER LINCO with focus on the final
products. The major part of the products
produced on the new plant is transferred
to the new further processing plant
recently constructed by AliBal. Therefore
the processing plant is optimized to
this purpose.
The new plant features some of the
latest technology from BAADER LINCO
and is the first complete APS solution in
Venezuela. The plant is equipped with
2 Breast Deboners model 656, thigh
and drumstick deboning with machines
from our partner Steen FPM and with
6 LINCOFlex High Speed Belt graders
where every final product is classified
and sorted out.
BAADER LINCO is honored by the trust
shown by AliBal to be a partner in this
project.
Mis P olli t os
First ProFlex Premium in Venezuela
In Los Teques only a short drive from
Caracas we find the cut-up and deboning
plant of Mis Pollitos equipped with
BAADER LINCO equipment and running
6,000 birds per hour. Mis Pollitos is the
first customer in Venezuela to purchase
the automatic ProFlex Premium Cut-Up.
Mis Pollitos is a partner for BAADER
LINCO in the developing project of the
semi-automatic rehanging to cut-up. We
are happy that Mis Pollitos has accepted
to team up with us in the developing
project which we expect to finalize in
the first quarter of 2012.
The chilled eviscerated chickens that Mis
Pollitos receives from other suppliers are
rehung on a ProFlex Premium Cut-Up line
which features in-line weighing, by-pass
and selective drop off parts. Some of the
parts are transferred to deboning and
deskinning. The chicken parts end as a
mix of deboned parts and undeboned
parts which are graded and batched on
LINCOFlex Belt Graders with product
identification as a feature.
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Poultry newsletter
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O p t i m i z e y o u r logis t ics
Rethinking poultry grading and packing
Poultry processors are constantly facing the changing consumer demands which again means that a poultry processor typically has a big range of products and needs to be
flexible at short notice. With this in mind, BAADER LINCO
has rethought the traditional grading solutions to be able
to support the challenges of the modern poultry processor.
Flexibility, throughput and meat quality are all essential factors to take into consideration when designing a modern
grading and packing solution.
The foundation of every grading system is the weighing
input. Our latest generation of dynamic scales is characterized by high performance ensured by our unique Tara
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principle compensating for sticky parts to the conveyor belt
during normal poultry production.
The newly developed units such as the dynamic scale and
new hygienic conveyors are concepts integrated in our
new FlexPacking System and InLine Packing Grader. Both
systems are developed in close cooperation with our customers. BAADER LINCO seeks to meet customer demands
by using simple techniques to achieve far-sighted, flexible
grading and packing solutions which can easily be custom
fitted.
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InLine Packing Grader
The InLine Packing Grader breaks with the traditional way of
packing by centralizing the packing operation and making
the introduction of the packing material more efficient by
having a single point of infeed for trays.
The breaking point is the high utilization of packing operators. The work flow is fluid and equally distributed among
operators.
Information is power
ProLogix provides a complete Production Management Software. It is a modular system that can be expanded and
maintained easily by upgrades.
- Pace control for high and continuous throughput. Speed
is no longer decided by the packing operator but by the
system.
- Operator comfort by centralizing the packing function
directly in front of the operator.
- Reduced product and material handling for better hygiene and simplified packing functions.
The system controls the activity around the Packing Grader
and extracts valuable production information.
• Real-time production reports to be acted upon immediately
• Visualize line performance directly on shop-floor
• Registrer down-time or product deviations
• Yield analysis
• Packing instructions directly on shop-floor
• Identify bottlenecks in production
• Real-time monitoring and control of dynamic weighing
and packing
• Set-up of packing jobs
• Service tools for maintenance and troubleshooting.
Improving your business results is an ongoing process. You
plan, you act to achieve the planned goals, you check and
you react on the feedback. ProLogix helps you achieve your
goals.
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O p t i m i z e y o u r logis t ics
FlexPacking System
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FlexPacking System
BAADER LINCO strives to integrate automation and flexibility in this grading solution. Hereby we help our customers
meet requirements for small and ever-changing batches for
more individual end-products.
Ergonomics
Each packing station brings the products direct to the operators so the reaching length is reduced and the lifting is
minimized. Individual height adjustable packing platforms
are an option.
Flexibility
The grader can handle a wide range of products and offers
a smooth product flow:
- Packing to both tray and bulk on the same grader
- Packing to weight, number or weight/number
- Packing mixed products on the same grader e.g. legs,
drumsticks, quarters and whole legs
Hygiene
- Open constructions
- Welded connection points – weldings on the outside
-Foldable side rails
- Easy to change belts
- Reducing the manual product handling to a minimum
means better hygiene.
Food Safety
Reducing the manual product handling to a minimum means
better hygiene.
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Pgradually
oultr
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t t e r www . linco f ood . co m
e tunnel
increases
5l
toe50%,
eating a very gentle stunning process. The
Make
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. co the
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most of t
The Maxiload modules
rds remain fully stunned until they have passed
Mmachine,
A X I L Omeaning
A D L I that
V E they
B I are
R DnotH A N D L I N G S Y S T E M
e killing
stable, making them ea
xposed to any further handling after being
aded into the Maxiload crates at the farms.
ensuring ample airflow
The design also facilita
Animal welfare is good business
l dumping from modules is totally avoided.
omplete process control
ue to a unique conveyor design, the patented
AS system can be adjusted to meet the
quired rate of birds per hour. High-precision
as sensors are placed throughout the tunnel,
nding data to a computer, which controls
e entire system. All stunning parameters can
Easy loading & unloading of modules
e adjusted to suit variations with
at thetruck
reception
or fork lift
oint, due to line speed changes or change
bird sizes.
With the installation of the LINCO
Maxi-load Live Bird handling system,
your company’s live bird handling process is streamlined, and you will see
increased live bird quality, significant
hygiene improvements, and reduced
labour and transportation costs. The
system, capable of handling up to 10
crates per minute, features the unique
tress-free shackling
egardless of the shackling method used, the
unned birds ensure a stress-free process for
e birds as well as the shackling staff. Bird Ensuring welfare and
saving money
amage is prevented, and eliminating the use
electrical stunning also prevents blood spots
nd other meat damage. As the birds do not
Modules are easy to load on
the truck using forklift
ap their wings, the system also greatly reduces
e formation of dust at the shackling station.
ON THE ROAD
Less damage to birds during
catching because of the
easy access to the big
crates
Hydraulic roof – se
LINCO Maxiload plasticWhen
crate,the
thetruck
larg-is read
est plastic crate available
the market.
theonload
is fixed by a h
Each crate can handle 85
160 in
kgjust
(de-10 seco
the - load
pending on bird size). The system has
which may come loose
destackers and restackers, and all crate
The roof also pr
and module handling is driver.
now automated
rain
or
the heat
so one fork lift operator can handle
allof the
full modules from the truck and all clean
modules back to the truck.
Saved $ 300.000
The Maxiload system s
on transport costs comp
transport systems; day
long run, that amounts
One LINCO custom
than $ 300,000 in
switching to a Max
Optimized airflow
through the drawers
Exellent ventilation on the
truck during transportation
= maximum loads all
year round
BI G CR ATE S &
S TR O NG M O DU L E S
Controlled Atmosphere Stunning - the
chicken is falling asleep as the amount of
oxygen in the body reduces = No stress
in hanging section for bird nor worker
No pushing and pulling of full
crates because of the module
system where the crates are
filled from the bottom
Big crates make it possible
to hang from both sides of
the conveyor.
CO2 concentration
ranges from 5% – 50%
Investment w hich pays off
Automatic or manual catching
AT THE FARM
Washed/disinfected modules
return to farm
Washing/disinfection of modules and
crates separately and together
< Easy access to module - loading
crates from bottom
Stressless hanging in lighted room of
CAS stunned birds >
14
Stressless hanging
AT THE PLANT
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Poultry newsletter
L I V E B I R D H A N D L I N G S Y S T E M a t R ed L ea
Maxiload moves Down Under
Red Lea Chickens was founded by
John Velcich in 1957 and is still based
around the family home in Blacktown,
Sydney, Australia. The Red Lea empire
now processes 25 million birds per year,
employing over 1000 staff and has 42
of their own retail outlets in Sydney and
the surrounding towns.
As one of the pioneering innovators of
food processing technology, Red Lea
Chickens has installed the very latest high
speed LINCO processing equipment in
their Blacktown processing plant. Not
only will the plant now be capable of
processing 12,000 birds per hour with
a live bird size variation spreading from
1.6 kgs to over 4 kgs, but the plant will
have the very latest technology in live
bird handling systems.
Red Lea is the first processor in the
Australasian Region to
install the Maxiload Live
Bird System. The LINCO
Maxiload Live Bird System
will increase live bird
quality; provide significant
hygiene
improvements
and reduce labour and
transportation costs. Red
Lea has always been
very conscious of the
animal welfare aspect
of
processing
poultry
and the new Maxiload
system, which incorporates
Loading and destacking of modules on Maxiload
CAS - Controlled Atmosphere Stunning
the latest technology in Controlled
Atmosphere Gas Stunning, will provide
the plant with the best quality live birds
at the most efficient cost structure.
M A X I L O A D L I V E B I R D H A N D L I N G S Y S T E M f or t u rke y s
Big birds, big advantages
The destination is Codlea, Romania,
approx. 200 km north of Bukarest. The
plant is Galli Gallo, the biggest turkey
processing plant in Romania which
is equipped with a complete LINCO
solution including Maxiload - Live Bird
Handling System with CAS stunning.
In general, the Maxiload system for
turkeys features the same advantages
as the Maxiload
for
chicken,
but
naturally
designed
with
the size and
weight of the
large birds in
mind. As some
modern turkey
plants
are
processing birds
from 5 to 23 kg
live weight, the
LINCO
turkey
Turkey modules with equipment
is
doors for easy load- constructed
to
ing
handle all sizes
of birds.
From Farm to Processing Plant
The turkeys are easily and quickly
loaded into the Maxiload modules at the
farm and transported to the processing
plant. The crates for turkeys are supplied
with a door in front as an option suited
for automatic catching machines. By
using automatic catching, the turkey will
maintain constant feet contact with the
crate and thereby the turkey remains
calm and the stress level in the bird will
be reduced. Once in the drawer at the
farm, no operator needs to handle the
turkey until it is completely stunned.
Suspending the turkey then becomes a
simple operation of guiding the feet into
the shackle without lifting the heavy bird.
Controlled Atmosphere Stunning
The Maxiload system provides the lowest
consumption of CO2 on the market.
Blood spots are virtually eliminated in
breast meat, wings and thighs thereby
giving a higher yield on the bird as
less trimming
needed.
is
Maxiload benefits for Turkeys:
- Labour saving
-Improved animal welfare
ergonomics
- Improved meat quality
and
Stressless birds
The turkeys processed at Galli Gallo
come from farms in the area or can be
picked up as far away as in Slovakia
or Hungary. All transport and handling
are stressing factors, but at Galli Gallo
transportation of the turkeys with the
Maxiload system combined with a high
focus on the live bird storage area with
correct illumination, temperature and
classical music played for the birds have
all together increased the factories´
yield.
15
Poultry newsletter
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/
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- f or C h icken B reas t S ingle Fille t s & B u t t er f lies
X-Ray Bone Detection
Improved cost of ownership
BAADER LINCO is proud to present the
2nd generation of x-ray bone detection
with improved cost of ownership. We
expect to start the launching process in
2012.
The X-Ray Bone Detection model 886
detects bones and foreign objects like
stones, glass and metal in chicken
breast single fillets or butterflies and
can be positioned in line with the
Breast Deboner model 656 or manual
deboning lines.
Real time defects reporting
The advantages of the X-Ray Bone
Detection model 886 are the high
performance in bone detection and the
real-time defect reporting. The real time
reporting can be used to maintain the
optimum cutting path performance of
Breast Deboner model 656.
Features
X-Ray Bone Detection model 886 has
high X-Ray safety and improved tube
lifetime due to low energy system and
it is equipped with a Touch Screen
interface for production and service.
16
The X-Ray Bone Detection model 886
is supplied with an adapted discharge
conveyor to deflect the detected fillets
for subsequent trimming as part of the
system.
Benefits:
• Image quality: max. 0,15mm
resolution=1pixel (2mm bone = 12
pixels)
• Low cost of ownership due to
substantially improved durability of
X-Ray tube
• Hygienic
design
with
good
accessibility for cleaning and
maintenance due to C-frame design
• Quick release and dismantling of
the belt
• High image quality and high level
of image analysis due to improved
signal to noise ratio
• High X-Ray safety
• Low energy system
• Robust and reliable construction
• Hygienic water-cooled system - no
air exchange
• User friendly controls via touch
screen
www . linco f ood . co m
/
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Poultry newsletter
A f t er sales and service
Spare part sales
Together, the BAADER Group and LINCO
Food Systems are a global organization
committed to quality and partnership.
This includes our support and expertise
on spare parts.
We manage the spare parts sales for
the poultry business from Denmark,
in cooperation with our dedicated
representatives and distributors close to
our customers.
Although our product line and the
companies have grown considerably,
our spare parts are still designed
and manufactured at our facilities in
Holland, USA, Germany and Denmark,
using the same high quality and skilled
manpower.
The BAADER Group and LINCO Food
Systems are constantly improving our
spare parts service, and we know
that availability of spare parts play an
important role at any plant. Therefore,
we value speedy delivery of spare parts,
high quality and professional advice for
the benefit of your business. In case of an
emergency, spare parts can be provided
within short time.
Our spare parts logistics are able to
provide parts from our central stores
worldwide:
• Re-fill of normal wear and tear
parts, which are used for preventive
maintenance
• Emergency parts – which are needed
in case of break down
We know the importance of spare parts,
and that future business requires a
proactive handling.
Our main areas are:
• Recommended spare parts
• Technical clarification
• Follow-up on spare parts quotations • Quoting spare parts based on field
technicians’ reports
• Proactive quoting of spare parts
Excellence in supplying and handling of
spare parts!
Meet us here in 2012
VIV Russia, Moscow
17 - 19 May
Polagratech, Poland
8 - 11 October
IPE, Atlanta
24 - 26 January
CFIA, France
13 - 15 March
Aprogromesh, Moscow
8 - 12 October
EuroTier, Germany
13 - 16 November
VIV China, Beijing
23 - 25 September
Gulfood Dubai
29 - 22 February
Saudi Agriculture
23 - 26 September
VIV India
22 - 24 February
MERCOAGRO, Brazil
18 - 20 September
AVEC & Cerdos, Argentina
11 - 13 July
SAPA-AVI, AFRICA
29 - 31 May
17
Poultry newsletter
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/
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Firs t processing : f ro m L ive bird t o picking
Are you reaching your full potential?
Do you recognize any of these
common problems?
- Blood spots and bruised wings
- Broken bones
- Remaining feathers
- Skin damage
Live bird reception
- Correct lairage, time and
conditions
BAADER LINCO is your partner in
finding the optimum solution in first
processing. Based on individual customer requirements BAADER LINCO
analyses each step throughout the
process.
Controlled Atmosphere
Stunning (CAS)
- Is CAS an option?
- Lairage
- Space in reception
- End product requirement
Hanging
-Illumination
-Ergonomics
- Bird stress
Electrical Stunning
-Time
-Frequency
-Voltage
Killi
- Choice of killi
We know First Processing
Carcass Care®
Carcass care means careful and responsible processing of
every single bird, making sure that no flaws occur which
could influence subsequent processing.
How to make the perfect setup
• In order to create the perfect setup, there is a list of parameters you must control to get the best relation between
bleeding, scalding and picking. The best meat quality
and yield require avoiding skin damage, cooked breast
meat, melted fat or feathers left on the bird.
18
• LINCO knows the process. In every plant individual parameters, which may even vary between flocks, must be
taken into consideration.
• Our goals are: No injuries during the first processing, a
maximum yield, welfare for both workers and birds and
an optimization of production flow - This is what we call
Carcass Care®.
ing
ing method
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Poultry newsletter
Each step throughout First Processing is crucial but cannot be evaluated
separately. The close dialog between
customer and BAADER LINCO will
reveal important data about market
situation, end consumer demands
and internal logistics. It is an ongoing
upstream and downstream evaluation
based on the incoming data in order
to offer a customized total solution.
www . linco f ood . co m
/
Bleeding
Scalding
- Bleed out balanced with
scalding process
- Balance between time,
temperature and end
product caracteristics
Picking
Evisceration
- Picking set-up according to
- Bird size
- Bird variation
- Scalding
- End product
- Shackle type
- etc.
Highe
r
optim yield is ob
t
izing
the pr ained by
live b
ocess
ird to
f
pickin rom
g
LIVE BIRD
RECEPTION
FIRST PROCESSING
UPSTREAM
CUT-UP
DEBONING
CHILLING
DOWNSTREAM
BATCHING
PACKAGING
LIVE BIRD CATCHING
AND TRANSPORTATION
FINISHED
PRODUCT
19
Member of the BAADER GROUP
LINCO Food Systems A/S
DK-8380 Trige
Denmark
Telephone: +45 86 23 14 55
Fax: +45 86 23 14 44
E-mail: [email protected]
www.lincofood.com
BAADER - JOHNSON
2955 Fairfax Trafficway
Kansas City
Kansas 66 115, USA
Telephone: +1 / 913621-3366
Fax: +1 /913 621-1729
E-mail: [email protected]
www.baader-johnson.com
BAADER
Nordischer Maschinenbau Rud. Baader
GmbH+Co.KG, Geniner Strasse 249,
D - 23560 Lübeck, Germany
Telephone: +49 / 451 5302-0
Fax: +49 / 451 5302-492
E-mail: [email protected]
www.baader.com
Keep the chickens calm during stunning with
new developed High Frequency Stunner
When redesigning the High Frequency Stunner, LINCO Food Systems A/S
learned that the University of Bristol
was working with the industry and EU
on new regulations regarding the stunning process. Therefore it was natural
for LINCO to team up with the University to design the best high frequency
stunning solution for poultry processors.
In all processes, LINCO is doing the
utmost to preserve the inbound quality
of the birds delivered. The most significant task is to avoid injuries to the bird
which could have a negative influence
on the quality of the finished product.
With this starting point, LINCO recognizes the below important criteria for
the stunning process:
-The chickens are transferred to the
Stunner in a smooth movement.
-The stress level of the chickens is
reduced to a minimum. Stress immediately prior to stunning will
lead to a deterioration of the meat
quality.
-The chickens are calm when entering the stunning tub in order to
obtain full contact with the water
and hereby instant stunning.
-Full contact with the water in the
Stunner for 6-8 seconds to ensure
effective stunning, until the chicken
dies from bleeding after the Killing
Machine.
High Frequency Stunner 2010
The HFS 2010 ensures that the birds
are guided into the machine by means
of a height adjustable ramp which
gently raises the head of the chicken
and afterwards drops the head in the
water to make fast contact with the
water. Also, space around the birds
has been created to minimize the risk
of bird contact with live material. The
depth of water in the tub is designed
to have all birds stunned, despite of
difference in size.
When developing the HFS 2010, hygiene has been taken into consideration. Thus, all parts of the tub can be
opened or removed in the cleaning
process which means that bacteria,
such as salmonella and campylobacter, will be eliminated during cleaning.
At the same time, the design makes it
possible to watch the birds during operation in order to facilitate a possible
height correction by means of a hand
pump mounted on one of the sides.
Working with the scientific
expertise
It has been inspiring for the engineer
in charge of the project to work in cooperation with the University of Bristol
and to find the relevant expertise useful in the process when developing.
More specific, the University of Bristol
has assisted LINCO in the interpretation of the EU regulation and advised
on optimal handling of the chickens in
connection with the stunning process.
The HFS 2010 has been developed
according to EU regulation (EC No.
1099/2009). This regulation has
been passed with the aim of improving the animal welfare in the killing
process.
Based on these guidelines, LINCO
has developed a stunner which in an
optimal way takes animal welfare,
regulations and not least the meat
quality into consideration. With the
HFS 2010, the slaughterhouse will be
able to:
- Achieve the best possible animal
welfare
- Achieve the least possible stunning injuries
The HFS 2010 has been on the market for about a year and was one of
the news at the BAADER LINCO booth
at the 2011 version of IPE in Atlanta.
LINCO has great expectations for this
product which has been well adopted
by poultry processors and is implemented at processing plants around
the world.