15,000 bph processing – a proven solution

Marel achieves unrivaled reliability at all-time high speed

Celler Land People

Taking into account the fast-growing and urbanizing world population, the production of poultry meat is expected to increase considerably. Processing plants need to intensify their operations to keep up with consumer demand.

There is an unmistakable call for even higher processing capacities than today’s maximum of 13,500. Marel timely foresaw this trend and started developing solutions to handle a line speed of 15,000 bph.

Marel is the world’s first supplier of integrated 15,000 bph lines. Dealing with such high speed, there is no other way than to have paramount reliability; if not, every minute of malfunctioning means 250 lost chickens!

Therefore Marel has profoundly tried and tested its new 15,000 bph configuration before launching it at the market. After this long period of extensive research and development, it is labeled as a truly proven solution.

Keep control

All systems are set for a processing speed of 15,000 bph. From live bird handling with ATLAS and stunning with CAS SmoothFlow, via evisceration and chilling, up to the distribution line, every process step solidly handles this all-time high speed. Innova software runs in the background to supervise all fast processes plant-wide.

The ATC tension control system keeps the powerful forces of the lines under control, while they move at an incredible speed. The all-new LineLink DE and LineLink EC transfer units seamlessly hand over products from one shackle type to another, while they travel through the processing stages.

Traceability

The entire 15,000 process is automated and online. Strategically positioned data capture sensors, IRIS vision grading systems and SmartWeigher - the world's fastest precision weigher - combine to provide a wide variety of useful data.

This data, collected from all interconnected systems, allows the Innova Food Processing Software to offer full traceability to customers. It has a comprehensive overview of the journey of each product, from the reception of the birds to the dispatch. End-to-end traceability is essential to reassure customers about product quality and food safety.

Poultry processing plant

The all-new LineLink DE and LineLink EC transfer units seamlessly hand over products from one shackle type to another, while they travel through the processing stages.

Proven solution at Celler Land

Some time ago, Celler Land Frischgeflügel in Germany was the first poultry processor in the world to step up to a line speed of 15,000 bph. Celler Land Managing Director Richard Wenneker tells about the necessity of an accelerated processing line: “Our poultry market was projected to grow. We, however, had already two shifts of people working and couldn’t do any more products per day with this level of performance and quality, unless our line speed increased.”

Hendry Kuijpers, Celler Land Plant Manager adds, “Together with Marel we saw the perfect opportunity to expand the 13,500 bph capacity to 15,000.” Having experienced the all-time high capacity system for a prolonged time, Celler Land’s plant management can only express its ultimate satisfaction.

Forefront of the industry

“It is always a pleasure to visit the Celler Land Frischgeflügel team who are at the forefront of the poultry industry. Frischgeflügel and Marel have been innovation partners from the very beginning. I was impressed while visiting Celler Land where we are achieving record processing speeds of 15,000 birds per hour. Every single point in the chain needs to be precisely configured and work seamlessly to accomplish this extremely high throughput,“ says Árni Oddur Thórdarson, Marel CEO.

“Consumer tastes are changing fast, and there is a growing demand for more variety in supermarkets. It is critical that secondary processing steps be smart and interconnected with primary processing to meet these market needs. With our comprehensive Innova software solutions and interconnected equipment, we enable poultry processors to supply products that are of the highest quality, affordably priced, sustainably produced and fully traceable throughout.”

Uncompromised

All-time high processing speed is not a goal in itself. Already proven in practice, the fast operational pace of Marel’s 15,000 bph lines brings about a significant increase in performance and yield. Achieving the lowest production costs, it is of utmost importance that the highest quality and efficiency remain uncompromised.

Sustainability benefits from the efficiency increase too, since only a slight modification of existing machinery is needed to produce a considerably larger amount of products. In this way, the environmental footprint per broiler will reduce.


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