In China, retired layers usually go to small slaughterhouses for manual processing. Valued for their strong flavor, these “old hens” are sold as whole birds, often for traditional soups. Seeing the industrial potential of this niche, Shanxi Xinhui Food is installing China’s first automated evisceration line for layers. The 12,500 bph JBT Marel system boosts throughput and cuts reliance on manual labor.
By automating the layer evisceration process long thought impossible to mechanize, the company is a true pioneer in the Chinese poultry industry. While many broiler processors in China face heavy margin pressure, Xinhui stays profitable by processing and selling retired layers as whole birds.
Processing layers is very different from processing broilers. Layers are older birds with thinner legs, tougher carcasses, and fully developed intestines. Their reproductive systems may also contain unlaid eggs during processing. Managing these challenges in-line requires precise control and careful adaptation of the equipment. With JBT Marel’s support in automating the process, Xinhui is confident to handle layers effectively.
Eva van der Velde, JBT Marel’s process technology expert, will personally oversee the on-site commissioning. She explains: “Processing layers calls for special attention and a customized approach. Due to their stronger build and different shape compared to broilers, great care must be taken—not only to avoid damaging the equipment, but also to protect the products from incorrect infeed or outfeed handling. Another challenge is speed—processing 12,500 layers per hour has never been achieved before. And finally, local Chinese preferences regarding the appearance of the end product must be taken into account. That’s why maintaining close contact with Xinhui is essential to fully understand and meet the exact requirements.”
Processing layers calls for a customized approach. A speed of 12,500 layers per hour has never been done before.
Eva van der Velde
JBT Marel Poultry Process Technologist
Most of the layer processing steps—such as stunning, defeathering, and chilling—are largely comparable to those in a broiler plant. “Evisceration, however, is the most critical stage. This is where the greatest differences emerge,” says Eva van der Velde. “The eviscerator will be equipped with special parts designed for layers to ensure the highest possible efficiency while keeping the product intact. At the same time, the settings and guides need to be precisely adjusted.”
Via the JBT Marel Sigma overhead conveyor, the defeathered products enter the automated evisceration line, that starts with the VC-16 vent cutter and the VO-20 opening machine, followed by the Nuova 24 eviscerator. Viscera packs are automatically rehung onto the separate pack line, after which giblet processing is carried out manually. At the back end, Xinhui uses a FIM RotoVac final inspection machine for the last quality check.
Shanxi Xinhui Food was established in 2013 and is a provincial key leading enterprise in agricultural industrialization, specializing in retired layers. The company has over 120 employees and an annual processing capacity of 13.5 million birds, with plans to expand to 25 million using the new production line. Its sales network covers 34 provinces and municipalities across the country. The company markets its products under two major brands, Jinxinhui and Jinxianyuan, both of which enjoy a considerable reputation.
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