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01 2015 NEWS Further increasing your profitability with the new back meat harvesting solution for the Rapid Plus breast deboner M3.0 in this edition Improved tail feather puller Frisia Food Meyn Mags automatic giblet harvesting solution Back meat harvesting solution for Rapid Plus breast deboner M3.0 Meyn Technology Services Meyn worldwide afdeling 4Improved tail feather puller 5 Frisia Food incorporates new Meyn technology 6 Meyn Mags automatic giblet harvesting solution, combining optimum yield and lowest operational cost 8 Further increasing your profitability with the new back meat harvesting solution for the Rapid Plus breast deboner M3.0 9Velskaya successfully incorporates Physic HS and Rapid HQ in existing plant 10New: Meyn technology services Optimizing your production process 12 Meyn successful in Colombia 13Grupo Melo continues to expand for full flexibility in end products 14San Isidro installs new FCF Food Servicer line 14San Fernando to process traditional and KFC cuts on Meyn Food Servicer cut up system 15Columbia Farms replaces defeathering line 2 panama INTRODUCTIoN The world population continues to grow and the level of prosperity in upcoming markets is increasing rapidly. Global demand for animal protein is expected to grow accordingly. More mouths to feed means major market opportunities for your business, but it also brings serious challenges. How can you feed the world responsibly without jeopardizing your competitive edge and business continuity? Continuously increasing feed prices, difficulties in finding – and foremost keeping – skilled and motivated personnel as well as the compliance with hygiene regulations and environmental restrictions, make it all the more important to raise your efficiency in getting the most out of your process. Working with Meyn means you can rely on intelligent, innovative, customized and sustainable solutions that enable you to meet the challenges of today’s market and tomorrow’s society. Your success is our goal. Every day, all over the world. Meyn. Answers to your challenges. Follow us and you’re always up to date 3 SLAUGHTERING Improved tail feather puller The Meyn tail feather puller now removes the long tail feathers from the tails more effectively. Removing the tail feathers with a dedicated plucker makes the plucking process more effective as the main pluckers can be set to work in other areas of the carcass in a more gentle process. The tail feather puller consists of two rollers that are mounted close together. The position of the rollers is set in such a way that the tail feathers are caught in between the rollers, effectively pulling the feathers from the tail. New developments The design of the tail feather puller has been significantly improved: Improved bearing construction for the pulling rollers. This new design significantly improves the lifetime of the bearings compared to the old design (less maintenance). Improved cleanability and maintainability because of the new hinge construction to rotate the module off-line. The height and the distance to the product can easily be adjusted during production to compensate for different size products. An open construction to prevent accumulating feathers. Adjustable product guides to support size variations. Improved in-feed flights on the rollers, to prevent the thighs from being damaged. Improved machine design for maintenance (grease nipples and better access to components). A stand alone supporting frame. 4 Frisia Food incorporates SLAUGHTERING new Meyn technology Frisia Food has a tradition dating back more than This year, Frisia decided to incorporate several 60 years in the poultry industry. The original newly developed Meyn machines into their existing company (J. de Vries & Zn BV) started out as a process. In the slaughtering department, the new traditional chicken processing plant and developed tail feather puller was added, making the plucking into one of the larger processing plants of The process more efficient. For the automatic rehanging Netherlands. In 2010, the slaughtering activities of J. from the slaughtering line to evisceration line, the de Vries & Zn BV were acquired and continued under newly developed Syncom rehanger was installed. In the name Frisia Food b.v. The company is situated in the evisceration department, the new fat retention Haulerwijk, in the Northern part of The Netherlands. machine and cropping machine result in a reduced wear and tear. Over the years, the plant has been extensively refurbished. In 2011, the complete slaughtering Frisia is also the first company to be operating the department was replaced with new equipment, new Meyn Mags automatic giblet harvesting solution. such as Quest stunner, electrical stimulation, Anton Storteboom, CEO of Frisia Foods: “We are very footpad inspection system and jet stream scalder. content with the results of the Mags. The liver quality is Also incorporated in this department is a complete very high and the reliable and constant performance and feet processing line as the company exports their optimum end product presentation is exactly what we feet products to Asia. One year later, in 2012, the need in this highly delicate part of the process.” refurbishment of the evisceration department took place and a new 12,000 bph Maestro evisceration line was installed. 5 EVISCERATION Meyn Magscombining automaticoptimum giblet The Meyn Mags automatic giblet harvesting solution is a fully automatic and highly reliable solution that seamlessly integrates into any existing or new Maestro evisceration system. As a result of the effective organ separation principle, optimum product presentation and the highly competitive and constant yields, the solution produces maximum “A” grade livers and hearts with minimum inspection requirements and virtually no rework. The complete solution includes all necessary auxiliary equipment and services that are needed to maximize benefits and has the lowest operational cost – labor as well as maintenance – in the industry. 6 EVISCERATION harvesting solution, yield and lowest operational cost The harvesting modules, with a maximum capacity of 6,000 packs per hour each, can be installed in any place along the pan conveyor after carcass inspection. The system is very flexible regarding layout and can be oriented perpendicular or parallel to as well as on either side of the pan conveyor. The modules are constructed according to the highest safety and hygienic standards. Whatever the capacity or the products you make, Meyn can supply you with the optimum giblet harvesting solution. 7 DEBONING Further increasing your profitability with the new back meat harvesting solution for the Rapid Plus breast deboner M3.0 The all new back meat harvesting solution saves on labor and further increases your profitability in breast deboning. The solution allows you to automatically harvest the back meat separately with an undamaged structure giving it a unique presentation. When opting for back meat harvesting on the Rapid Plus, you will be able to increase the amount of back meat harvested, save on labor and reduce trimming losses. Example of calculation of additional revenues with the back meat harvesting solution: (calculation is based on front half processing, one shift per day for one year) Additional back meat harvested 7 g/bird = 84,000 kg/year x 0,80 Euro = 67,000 Euro Reduction trim loss (breast meat removed by trimming back meat) 4 g/bird = 48,000 kg/year x 2,60 Euro = 124,800 Euro Labor savings 5 people x 25,000 Euro 125,000 Euro = Total increase in profitability 316,800 Euro If you are looking at further improving your profitability and eliminating trimming labor and labor influences, the new Meyn back meat harvesting solution is the answer. 8 DEBONING Velskaya successfully incorporates Physic HS and Rapid HQ in existing plant The first phase of the extensive refurbishment of the formerly installed cut up system and with the highly Velskaya Poultry Factory took place without hardly accurate cuts much higher yields are realized. causing any production delays. Production could continue as normal even during installation, made The decision to opt for the Rapid HQ was largely possible due to smart planning and good cooperation based on the high yields obtained during testing between the Meyn engineers and technical staff of performed at the Meyn Demo and training center. Velskaya. After several weeks of operation at Velskaya, the Rapid has certainly met the high yield expectations The live bird handling department is equipped with a and has also resulted in considerable labor savings. new weighing system for crates. The newly installed Meyn QGS (quality grading system) allows to sort the In the next phase, the Physic cut up line will be bird quality in-line and with the data obtained, equipped with by-passes to further increase yield. improvement programs are made for the broiler Next to this, additional modules will be installed to farming. The Physic HS cut up system is able to extend the product range. handle a wider weight range of products than their 9 TECHNOLOGY SERVICES New: Meyn Optimizing your You are fully aware that continuous process improvements are the key to your success, but it is sometimes hard to see where they can be found. That is why Meyn now introduces Meyn technology services; to help you get a clear view on the possible opportunities in your process. Our technologists, with global experience in poultry processing, have all the knowledge it takes to benchmark your facility to the best practices. For this, one of our technologists performs a survey in your plant which will focus on a predetermined scope and objective. During the survey, the Meyn technologist will analyze, measure and monitor your process and talk to your operational and Q&A team. 10 technology services TECHNOLOGY SERVICES production process Based on the findings, a detailed report with Next to performing surveys, the Meyn technology recommendations will be made and presented team is also involved in scientific research & to management. The report will give insight on legislation (governments, branch organizations, possible cost reductions that can be achieved, but NGO’s) and keeps close contact with a prequalified will also highlight ways of potentially increasing pool of experts (universities and third parties). This your revenues. Over the past few years, Meyn has close contact with legislation makers also enables us performed many surveys and on average the cost to inform you in an early stage and advise or assist reductions per survey amount to EUR 382,000 and you in solving issues or improve processes which go increase in revenue could be as high EUR 2,000,000! beyond Meyn’s core business. And the benefit for you is of course that you can tap directly into this data base of information gathered by Meyn over the years. 11 WORLDWIDE Meyn successful in Colombia Colombia, with 47 million inhabitants and a consumption of chicken meat that is expected to reach 30 kilograms per person per year in 2015, has a poultry industry in full development and growth. In 2014, Meyn appointed a new agent for Colombia, R&M de Colombia ltda. Managed by Rodrigo Pardo Herrera who has over 15 years of experience in the Colombian market, R&M has established itself as a well known name for technological support in the Colombian poultry industry. Over the years, R&M has contributed to the renovation of the most important processing plants in Colombia. Pollo Fiesta S.A., a market leader in Colombia, is They are now planning an automation and located in the city of Bogota. In 2014, they installed an optimization phase and will install a complete FCF Compact line and BC40 breast deboner. 10,000 birds per hour Maestro evisceration line including cross cut opening machine to replace their existing manual evisceration operation. The Maestro evisceration line is able to handle the wide weight range that is processed and as a result of the small footprint of the line, fits into existing building. The promise of Pollo Fiesta to its customers is the “Fresh Colombian Taste”, which they can achieve with the daily deliveries from their surrounding farms. The company is celebrating their 40 th anniversary and sees Meyn as partner for their future growth. 12 WORLDWIDE Grupo Melo continues to expand for full flexibility in end products In 2013, Grupo Melo, Panama started the type cuts for parts that are distributed to their Pío refurbishment of its processing plant with the Pío restaurants. The Physic HS cut up line features installation of a crate arrival system, slaughtering all types of modules and by-passes and will allow line and ECP evisceration line. For 2014, the company Melo to make all the different cuts that are required. decided to include some new equipment in these Next to this, a Rapid Plus breast deboner including departments with the installation of an electrical new back meat harvesting solution will be part stimulator and a bird counter vision M1.0 in the of the expansion. The new secondary processing slaughtering department. department will be controlled by the Meyn mLogic distribution manager M5.1 and will give full flexibility. But the expansion continues with a complete renovation of the secondary processing department All produced products will be transported on belts to which is scheduled for the second half of 2015. the packing area where they are weighed and packed A new high speed weighing line including QGS in boxes. The entire packing area will be controlled by quality grading system will automatically distribute a CSB warehouse management solution which makes the birds based on quality and weight to either the sure that the right products are distributed to the Food Servicer cut up system or Physic HS cut up line. right channels. The Food Servicer cut up system produces specific 13 WORLDWIDE San Isidro installs new FCF Food Servicer line Avicola San Isidro, located in Quito, Ecuador, is one in Latin America, as they were looking for a solution of the largest suppliers of KFC products in Latin that could guarantee optimum yields, but would also America. Their entire processing site is dedicated to fit the limited floor space they had available. Also, solely processing KFC products. Early 2015, they will they acquired a new Meyn FCF Food Servicer line for install a new Maestro eviscerator 20 units, the first their first automatic 9-pieces cut up process. San Fernando to process traditional and KFC cuts on Meyn Food Servicer cut up system The San Fernando company already dates back to San Fernando currently has a manual cut up the late forties, when Julio Soichi Ikeda started its operation, but they now wanted to automate this business with 39 ducks. Over the years, the company process. They produce both the traditional cuts has grown significantly and is now the market as well as the KFC cuts (8+9 pieces) and have leader in poultry, eggs, pork and sausages in Peru. extensively compared the different options. One of Outside of Peru they export their products to Bolivia, their requirements was that they wanted to process Colombia, Ecuador and Panama. both type of products on the same cut up line and the Meyn Food Servicer cut up system was the only solution available that can do this. 14 WORLDWIDE Columbia Farms replaces defeathering line House of Raeford Farms, Inc., headquartered in scalder, four JM64 pluckers, one JMD2 plucker, Rose Hill, North Carolina, is a family owned, fully new tail feather puller, hock plucker as well as two integrated poultry company with processing facilities rehangers from slaughtering to evisceration. The located throughout the southeastern United States. rehangers hang the birds from the 8 inch slaughtering One of their poultry processing facilities, Columbia line to two 6 inch evisceration lines and is the first of Farms is located in Greenville, South Carolina its kind in the United States. and processes 11,000 large broilers per hour for deboning. Mr Luke Brewer, Plant manager: “We are very happy with the results of the new defeathering line. Over In order to improve their yields and overall plucking scalding of the birds has been completely eliminated, performance, Columbia Farms decided to replace both whole griller and boneless breast yields have their existing 6 inch defeathering line by a new 8 inch increased and quality checks confirm improved feather 11,000 birds per hour Meyn line. The newly installed removal.” line consists of a Quest waterbath stunner, jet stream 15 afdeling answers to your challenges. visiting address: Meyn Food Processing Technology B.V. Westeinde 6 1511 MA Oostzaan (Amsterdam) the netherlands postal address: Meyn Food Processing Technology B.V. p.o. box 16 1510 AA Oostzaan the netherlands phone: +31 (0)20 2045 000 Fax: +31 (0)20 2045 001 e-mail: [email protected] www.meyn.com Meyn Food Processing Technology B.V. is a subsidiary of CTB Inc. CTB Inc. is a leading global designer, manufacturer and marketer of systems and solutions for the poultry, pig, egg production, and grain industries. www.ctbinc.com All Rights Reserved. 16