Miyazaki Sunfoods puts its trust in GP

Remotely assisted installation of first GP system in Japan

Miyazaki Plant GP

In the Far East, Japan is a very specific market with its own ways of processing poultry. Live bird handling in particular requires its own approach. Broilers are transported from the growing farm to the processing plant on relatively small trucks, as big vehicles would be useless on the steep narrow roads in the mountains where the poultry farmers are. Until now, birds were transported in crates, which was not the best solution. It turns out that the Marel GP system with its compact containers is a perfect fit for the Japanese market. The installation of a GP system at Miyazaki Sunfoods is nothing less than a major breakthrough.

Due to the pandemic and travel restrictions, the GP system couldn't be installed at Miyazaki in the usual way. Normally, local engineers would work on site with specialists flown in from the industry head office in Boxmeer.

Successful remote support

To reduce delays as much as possible, it was decided to have the installation done by local engineers who would receive help from specialists in Boxmeer, Holland via online remote assistance. Testing and commissioning were also handed over to local engineers, even though they had no prior experience.

There were daily online meetings between local technicians in Japan and specialists in Boxmeer to discuss the challenges of such a remote installation and to make it as smooth as possible. This customized approach turned our Japanese Marel engineers into specialists overnight. Together, teams at either end of the world tested and commissioned according to the book. Checks and double-checks took longer than usual, but this was needed to make sure that decisions were 100% correct and without rushing. In the end, it all turned out very well.

Complete confidence

Once commissioning and training were complete, the GP system was completely integrated into production. After having seen it functioning flawlessly for several days, the management of Miyazaki Sunfoods expressed their complete confidence in the system, which is, by Japanese standards, a great compliment for Marel.

The GP system now operates day after day in Miyazaki’s processing plant. Performance and yield results are exceeding expectations. Compared to the old crate system, there's a world of difference. Handling of live birds from farm to shackle has become much more effective and hygienic.

Miyazaki Group Picture

Front row, left to right: Yoshiki Yamagata (Enatsu), Yukinori Omae, (MSF), Kazuya Iwasaki (Enatsu), Kazuhiro Harazono (Enatsu), Hiroaki Harada (Itochu). Back row: Yuya Nagao (Itochu), Tim van Schaik (Marel), Arie Tulp (Marel), Casper Beeker (Marel), Mr. Tanaka (Enatsu).

Improved labor conditions

The compact size of its containers is not the only feature of the GP system attractive for the Japanese market. Miyazaki Sunfoods was also looking for improved working conditions and labor savings. Right from startup of the system, Miyazaki has saved people on the live bird handling platform and at the shackling station. Employees' working environment and conditions have also improved significantly. This also goes for the catching crew on the growing farms. GP containers in the shed require less muscle power and fewer physical movements than crates. Over time, the catching teams will gain more experience with the GP system. As they get used to the ergonomic containers, loading speed will increase even more.

The GP system at Miyazaki has the option of accessing the PLC control system remotely for optimum control around the clock.

The first, but not the last

Miyazaki's GP system has shown itself a perfect fit for Japan's specific poultry processing conditions and has generated a lot of interest in the market. Miyazaki will be Marel's reference plant in Japan, providing the Japanese market with a local proven solution and showing the added value. Miyazaki's GP system may be the country's first, but it certainly won't be the last.

About Miyazaki Sunfoods

Miyazaki Sunfoods is part of Enatsu Shoji, a holding company that started in the chicken business back in 1900 in Miyakonojo City, Miyazaki province. Today, Enatsu Shoji covers all aspects of the supply line, from broiler production, processing, packaging and sales to distribution. Farms managed by the Company as well as contract farms take care of Enatsu’s broiler production. Birds are processed in the Miyazaki Sunfoods processing plant with products being distributed nationwide by the Enatsu sales organization. Contracts with food manufacturers, trading companies and supermarkets ensure that Enatsu’s chicken products reach the dinner tables of consumers throughout Japan.

company website: enatsu.co.jp

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