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Accelerate Growth: Full Line, Full Speed

Apr 16, 2024

Ensuring Full Processing Lines

If shackling workers fail to secure a bird in every shackle on the slaughter line, the foundational element of line efficiency is compromised. Ensuring that shackling is straightforward and that its efficiency is constantly tracked is critical.

Facilitating shackling from both sides of a live bird transportation drawer enables workers to supply birds more easily to a high-speed slaughter line. The task is further simplified and made more comfortable if the birds have been stunned with CO2 before shackling, thus facilitating the line to remain fully populated. The integration of a bird counter immediately post-shackling allows for precise monitoring of line utilization and immediate corrections if the shackling performance drops.

Implementing bird counting at strategic points along the processing line, such as post-picking or following transfer units where birds are prone to fall off the shackles, allows for meticulous tracking of bird numbers. This data enables the adjustment and precise fine-tuning of upstream processes for optimized processing performance and line utilization.

Advanced vision technology is now being implemented in new areas, such as slaughter lines and evisceration processes. This next-generation AI-based vision technology is self-learning, enabling it to expand its monitoring capabilities across various processes and even track empty shackles efficiently.

Sophisticated production management software uses the data input from counters and vision cameras to enhance bird allocation and distribution to downstream processes, meticulously considering capacities on the whole bird packing and cut-up lines, alongside meeting sales orders by the production's conclusion.

Vision technology operates seamlessly even at the highest processing speeds, facilitating the collection of diverse processing data crucial for optimizing production efficiency.

Achieving higher line speeds

Every poultry processor follows his or her path to business growth, and one path is to produce a higher number of products on the processing line to achieve a higher return on the line investment.

In high-speed production environments, processing equipment must be meticulously engineered to ensure products are correctly positioned at each stage of the process. This precise design is not only about maintaining a swift pace but also about safeguarding the quality of the product throughout its journey. Moreover, the equipment should be designed for durability, aiming to minimize wear and tear. This attention to detail in the design phase ensures that both the longevity of the machinery and the integrity of the product are preserved, enabling a seamless and efficient production flow.

On a high-speed slaughter line, specialized equipment like the Killing Machine must be meticulously designed to accurately guide and position the product, ensuring the integrity of the process.

As line speeds increase, the reliance on manual labour becomes a critical concern. To address this challenge, businesses must choose between scaling up the workforce significantly or embracing automation technologies.

Especially in the traditionally labour-intensive deboning process, processors are increasingly turning to semi-automated or fully automated solutions. This shift is driven by advancements in technology that now allow machines to mimic the adaptability of human workers to the birds' anatomical variations. Moreover, modern automatic deboning solutions provide remarkable production versatility, enabling the production of a diverse array of products using the same machine.

Automatic deboning has revolutionized the poultry processing industry by boosting line speeds without a corresponding increase in labour, all while delivering superior quality breast products and maximizing yield.

Protecting Uptime

To truly optimize return on investment, it's imperative to maximize available production time and minimize downtime. This necessitates machinery designed for easy maintenance, fast wash-downs, and durability to withstand the rigors of the processing environment. In the event of unplanned production halts, swift and efficient support is essential. While first-level support may involve trained plant personnel, BAADER takes the service responsibilities seriously, ensuring expert assistance whenever required. Our service team boasts both local support and global expertise, offering robust support for immediate needs and long-term maintenance alike. To discover more about our service support for poultry processors, follow this link.


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