From manual to automated poultry processing
A lack of suitable labour, the need to increase hourly throughputs or both are the main reasons driving poultry processors to opt for increased automation. Whatever the reason and whatever the throughput, Marel stands ready to help with advice based on many decades of processing poultry across the world. The company can supply suitable hardware and software solutions for all capacities backed up by first-class customer service.
First steps
When start-up processors move to an in-line process based on shackling birds to an overhead conveyor system, the first two process steps to be automated are always scalding and plucking. Both are critical for attractive product presentation.
Scalding is a function of time and temperature. The higher the temperature, the shorter the time, and vice versa. Scald time and temperature will depend largely on whether products are to be sold fresh or deep-frozen, air or water chilled. Other considerations are skin quality and product color. Marel offers five scalding profiles from the longest scald at the lowest temperature to a short scald at the highest temperature. These together with hourly capacity will determine the size of the scalder needed. Marel systems are modular and easy to extend when capacities increase and/or products change.
Marel offers a range of attack and finishing pluckers for all capacities from under 1,000 bph to 15,000 bph. When capacities increase or if a processor decides to move from deep-frozen to fresh products, adding the correct attack or finishing plucker is a very straightforward step.
Evisceration 
Start-up processors invariably eviscerate manually using specialist hand tools. As the business grows, automation will become increasingly attractive, not least because with higher line speeds some steps become ever more problematic. This is particularly true of the process of drawing the viscera out of the carcass.
Marel developed its Nuova CoreTech eviscerator with processors making the switch from manual to automatic evisceration, particularly in mind. CoreTech offers all the features and benefits of Marel’s well-known, globally established Nuova eviscerator. Where CoreTech differs from Nuova is that it does not transfer the drawn viscera pack to a separate pack shackle but deposits it over the back of the carcass. Vets can then inspect the pack and operatives harvest edible giblets manually. CoreTech ensures a cleanly eviscerated carcass and an undamaged viscera pack. Hygiene, quality, yield, and consistency all benefit.
CoreTech can handle from 2,000 bph up to 6,000 broilers per hour. At lower throughputs, Marel can supply its CoreTech eviscerators with only half the number of evisceration units. In this case, evisceration line shackles will be at 12” and not 6” pitch. When hourly capacities increase, the “missing” units can be retrofitted and additional shackles bought to convert the line from 12” pitch to standard 6”.
As CoreTech users approach 6,000 bph, they have the option of upgrading their CoreTech machine to transfer the drawn viscera pack to a separate pack shackle. Processors can then continue to harvest giblets manually or, alternatively, can start thinking about harvesting hearts and livers automatically. Even if giblet harvesting remains manual, harvesting from a pack shackle is ergonomically more comfortable and easier for supervisors to monitor. Giblet yields will usually be higher and quality could benefit too.
Quite simply, CoreTech is an eviscerator, which can grow in line with its user’s needs without the need to invest in a completely new machine.
Other evisceration line operations can be automated too. A combined venting and opening machine can replace vent guns and scissors, and a final inspection machine lung guns. The necking process can be automated too with necks being removed automatically and neck flaps cleaned of residual pieces of crop, esophagus, and windpipe. At the end of the evisceration line, a carrousel machine can wash all carcasses thoroughly both inside and out. Automation does not need to happen all at once but can be a gradual step-by-step process.
Chilling 
Immediately after evisceration, products must be chilled to prevent the growth of spoilage bacteria. How this is done will depend on whether products are to be sold fresh or deep-frozen.
If products are sold deep-frozen, water will be the chilling medium. The move to an in-line process will usually involve the installation of a counter-flow screw chiller. This well-established technology has three main advantages. The chiller’s transport screw ensures a consistent pass time. Carcasses and ice water or water chilled by flake ice move in different directions, so that carcasses move into ever cleaner and colder water. Last but not least, the air is introduced into the chilled water both to help the chilling process and to provide whatever level of water pick-up is allowed by local regulations. Marel counter-flow screw chillers are modular. Their extension to handle increased capacities is easy. A drip drum to remove excess water can complete the installation.
If products are sold fresh, often in outlets owned by the processor, air can be an alternative chilling medium. Processors usually start by air-chilling carcasses on racks in a cold room. This way of working can continue after the move to in-line processing has taken place. The time will, however, come when a separate chill line based on an overhead conveyor becomes attractive. This saves labour and guarantees a consistent pass time, ensuring top product quality and yield. It can also be extended at any time, opening the door to a completely in-line primary process, as carcasses can be transferred automatically into and out of the air chiller. Marel has many decades of experience in air chilling and is able to supply a complete air-chilling package.
The secondary process
Once chilled, products for sale whole must be graded, sized, and packed. At the lowest volumes, all operations will be manual. Operatives will work at stations equipped with scales and bagging aids. As volumes increase, the Marel Compact Grader, which automatically weighs and sizes whole carcasses, becomes an interesting proposition. The final stage will be the installation of a dedicated selection and distribution line equipped with in-line weighing and quality grading stations, to which carcasses are transferred manually from a water chilling system and either manually or automatically from an in-line air chiller.
Some carcasses will be cut into portions, some of which will be deboned typically into breast fillets. As markets mature, chicken portions and deboned chicken meat become increasingly interesting. Initially, cutting and deboning will be manual. Growing volumes will, however, prompt interest in systems such as Marel StreamLine, which help manual operatives become much more efficient and which allow plant management to supervise their work.
Automation of cutting and deboning will, however, surely come, driven by increased volumes, labor issues, or a combination of both factors.
The Marel ACM-NT Compact cut-up system is an excellent solution for doing all kinds of cuts. The system offers all the advantages of the globally highly respected ACM-NT system in a compact footprint. It is modular and offers a wide range of wing, breast, and leg-cutting modules, which will satisfy the needs of most markets. These can be moved manually in and out of line to allow for various cutting regimes. The yield and quality of portions cut on ACM-NT Compact compare with the very best manual butchery operations. When the business expands and if space permits, ACM-NT Compact can be easily converted into a standard ACM-NT system and most components reused.
When it comes to deboning, Marel can supply automatic in-line equipment for deboning breasts, front halves, thighs, and drumsticks.
By adjusting itself automatically to each breast cap, the Marel AMF-i intelligent breast cap deboning system debones a wide range of breast cap weights into a wide variety of different breast fillet products. The system is modular, allowing processors to begin by automating some filleting operations while leaving others manual. Their automation can happen later with the straightforward addition of the necessary modules.
Where markets permit, the unique FHF-XB front-half deboning system will also harvest shoulder meat together with the breast fillet, resulting in truly unbeatable meat yields.
Marel can also supply automatic end-of-line systems such as weigh price labelers, check weighers, and pack handling equipment.
Software
The move from manual to automatic processing need not be about hardware alone. Marel also supplies software products specially developed for the poultry processor. There are several Innova modules, which will be of interest to growing businesses. Innova PDS is the ideal tool for ensuring that each carcass is sent to the destination, where it can earn the most money. This could be for packing as a whole product or for cutting into portions and deboning. Innova can also digitalize warehouse management, replacing the need for old-fashioned pen and paper. As and when capacities increase, processors can buy further Innova modules.
In its most complete form, Innova can oversee production plant-wide from live bird hang-on to cold store. This allows plant management to monitor and control production from a central point. Innova can also provide full product-by-product tracking and tracing. Supermarkets and quick service restaurants are increasingly insisting on this.
Every step of the way
Every processor is different, making the transition from manual to automatic processing at different times and for different reasons. Usually, the cost and availability of suitable labor will determine when this happens. More subtle considerations such as more consistent yield and quality will also play their role. As line speeds accelerate, certain manual operations become more difficult to perform well.
No matter where in the world a processor is pondering the change from a manual to an automatic process, Marel is ready to offer a tailor-made solution to suit the processor’s own individual situation and market. The company offers a complete range of equipment, systems, and software covering all aspects of the process from live bird hang-on through to the final distribution warehouse. Whether you are processing fewer than 1,000 broilers per hour or 15,000 bph, Marel can be your partner, who will grow with you. Marel will help ensure you supply your wholesale, retail and food service customers with a wide range of consistently top-quality products processed safely and sustainably.
