A modernized and ultra-hygienic facility

A cleaner, more efficient site

The ATLAS system is housed in a new facility designed for maximum efficiency and safety. Modern SmartStack transport modules have replaced manual crate handling, enabling automated logistics and a higher level of hygiene. After transport, chickens rest in a quiet lairage area for about two hours before being shackled to the processing line. Once they have been stunned in their SmartStack trays in the CAS SmoothFlow system, broilers are transferred to a dedicated shackling area designed for operator comfort and efficiency. The entire live bird handling area including trucks, forklifts, lairage, shackling station and container washing is impeccably clean and free from dust or contamination.

A system praised for its innovations

ATLAS brings several major improvements compared to Rémi Ramon’s previous setup. The automatic system significantly reduces handling. It is efficient, safe and sustainable and is good for both employees and poultry, while ensuring compliance with regulations. It has also received recognition from Carsat (the French occupational health and safety organization) for its contributions to workplace safety and risk prevention.

1. Better working conditions

The ATLAS system was designed with special attention to operators. “The safety of employees and animal wellbeing are absolute priorities for us. With ATLAS, we have been able to create more ergonomic and safe workstations. Risks have been minimized, and working conditions improved,” stresses François Guillet. “The shackling crew are essential because they set the pace for the entire factory. It is therefore crucial to take good care of their working conditions and the ergonomics of the workstations, their breaks, their social facilities and their rest area.” At the shackling station, there is no more dust thanks to multiple, highly effective dust extraction systems and noise is effectively suppressed. The lighting is pleasantly bright and birds are unconscious during shackling. It is a calm, clean, and well-organized exemplary environment.

2. Animal wellbeing

The system boasts CAS SmoothFlow, which ensures the gentle handling of poultry. “We wanted a CO₂ stunning system for commercial reasons, for animal wellbeing, and for the highest meat quality,” explains François Guillet. The CAS technology minimizes stress to the birds, thereby benefitting their wellbeing and meat quality.

3. Enhanced cleaning

One of the strengths of the ATLAS system is the cleaning of transport modules, where excellent hygiene is an absolute priority. The SmartStack trays are designed for easy washing with no inaccessible corners. They can be thoroughly cleaned with hot water with almost no additives. This not only reduces costs but also minimizes environmental impact.

4. Resource optimization

ATLAS also helps optimize resource usage by reducing water and chemical consumption. “We use less water and fewer chemicals,” explains François Guillet. “Moreover, we can now transport more chickens per truck, lowering our carbon footprint.”

Virtual reality

Rémi Ramon used virtual reality (VR) tools before installation. It allowed for the visualization of future workstations including those with ATLAS in the live bird handling department. “Virtual reality enabled us to involve our employees from the early stages of the project, which made adapting new technologies much easier,” explains François Guillet. “We took the feedback from our employees to optimize their workstations.”

Seamless installation

Thanks to careful planning and the close, dynamic collaboration between the teams of Rémi Ramon and Marel, the ATLAS installation was completed smoothly and on schedule. The final commissioning was done over a weekend with almost no production downtime. “Marel supported us throughout the project. Together, our team and Marel’s team worked well together, each with their own expertise to create synergy. This is the best method to succeed in such a project,” emphasizes François Guillet. The teams from both companies worked hand in hand. “Exchanges were constant, both formal and informal, to achieve the best possible installation. It was a true win-win partnership.