Process

Process steps

Our product consisted of three important factors; Proper Hygiene, Freshness, and Good quality of Meat. It is crucial to understand that we offer the highest possible quality of Chicken products to our consumers. Since your well being, is our main concern..

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Step 1

Live bird handling

Smooth-running logistics in the supply of product make a very significant contribution to the overall efficiency of a poultry processing plant. Our live bird handling systems provide effective and animalwelfare friendly conditions for loading and transporting birds from grower to processor. The systems' in-plant logistics meet and even go beyond the highest demands as far as line speed, hygiene and durability are concerned.

Step 2

Stunning

We offer two methods for stunning poultry, both of which comply fully with the strictest regulations: electrical waterbath stunning (also available with high-frequency to safeguard product quality) and Multiphase Controlled Atmosphere Stunning (CAS). Practical experience with this welfare-friendly way of stunning has shown that blood spots and bone fractures hardly ever occur. The use of carbon dioxide in multiple phases, as applied in our CAS systems, such as the straight-line CAS SmoothFlow, is specifically mentioned in the list of stunning methods accepted without any additional requirements being necessary.

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Step 3

Killing

An accurate and consistently executed kill cut is a vital step in the primary process. The cut must ensure that the broilers bleed out fully before they enter the scalding process. The Stork killer is suitable either for making a neck cut (through the veins and arteries while the trachea and esophagus remain intact) or for making a throat cut (through the veins, arteries, trachea and esophagus).

Step 4

Scalding

The scalding process largely determines the appearance, color and visual quality of your end product. It can also influence yield and shelf life. Stork scalders ensure optimum heat transfer and precise temperature control, two vital characteristics of a first-class scalding system. Our scalding systems are easy to clean and maintain and use a minimum of energy. The innovative AeroScalder uses up to 75 % less water and up to 50 % less energy. It is the latest benchmark in top quality scalding systems and has been developed with environmental concerns very much in mind.

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Step 5

Defeathering

How a product is plucked is crucially important for its presentation. Plucking action will also determine the extent to which the epidermis remains attached to the product and is especially important if birds or portions from them are to be sold fresh skin on.

Step 6

Giblet processing

Giblets are popular and a profitable part of poultry processing. Processing them effectively and efficiently is most definitely in the processor’s best interest. Our equipment is suitable for the production of giblets for human consumption or for pet food. With the Nuova giblet processing system you can do all giblet processing operations manually, semi-automatic or completely automatic, ensuring the best possible yields, top giblet quality and optimum levels of hygiene.

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Step 7

Evisceration

With Stork Nuova automatic evisceration, the entire viscera pack including the crop is removed completely in a single operation. The viscera pack is separated immediately from the product and transferred automatically to a dedicated shackle on a separate pack processing line. This method has major hygiene and product quality benefits and saves labor.

Step 8

Feet processing

Feet and paws are popular. A feet processing system is therefore an interesting option for many processors. The system processes feet fully automatically from scalding through peeling and chilling. Its flexible and modular setup enables a profitable solution for every processor. Various high yield, high quality feet products can now be processed at the highest possible production capacities.

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Step 9

Blasting

Blast chilling is a method of cooling food quickly to a low temperature that is relatively safe from bacterial growth. Bacteria multiply fastest between +8 °C (46 °F) and +68 °C (154 °F). By reducing the temperature of cooked food from +70 °C (158 °F) to +3 °C (37 °F) or below within 90 minutes, the food is rendered safe for storage and later consumption.

Step 10

Chilling and maturation

For optimum shelf life, quality, freshness and food safety, end products must be effectively chilled. We offer various technologies, which chill birds to the correct breast core temperature without freezing wings or neck flaps.

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Step 11

Weighing, grading, distribution

The weight and quality of both whole products and parts can be determined automatically at various points in the process. The earlier grading takes place, the more accurate will be the decision-making for order production. Stork SmartWeigher and IRIS vision inspection can be implemented at four different locations in the plant to facilitate this: in the defeathering and evisceration department, in the distribution and the cut-up line.

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