Marine Harvest Ryfisk (Norway), wanted to improve their plant’s efficiency and increase the throughp..
1,000 bph greenfield plant in Ghana
17 Apr 2018
Aglow Farms aims at a market change
“We decided to enter the broiler processing market, because there is a big market out there, which until now has been completely dominated by lowpriced imported products,” says Kofi Brobbey Kyei. “Although Ghanaian consumers much prefer the look and taste of home-grown chicken meat, the market is flooded with cheap foreign products.”
Ghanaian consumers prefer the taste and the look of home grown products.
“It won’t be easy to compete with the low prices of imports; we will, however, find a way of changing the market by letting the consumer know the difference. Our poultry meat is locally produced, very fresh and totally different from imported products, which will have been frozen and stored for a long time abroad. By showing these differences, we hope to move the consumers towards our products. If we can achieve the volumes, with time we can compete. If we succeed in winning just 10% of this market, we will have to run our plant throughout the whole year.”
Kofi Brobbey Kyei explains why Marel Poultry was the ideal partner. “Both my daughter and I were investigating our options for choosing an equipment partner and the name Marel Poultry kept coming up. The two of us came to the same conclusion at the same time; that Marel Poultry could offer what we were looking for. We are very satisfied with the way the company reacts to our requests; they always keep their promises. Whenever we want something special, Marel Poultry responds very positively. We feel comfortable with this relationship.”
HEART OF THE PROCESS
In the brand new Aglow Farms greenfield plant, a Stork heavy-duty overhead conveyor, spanning over 80 meters (262 ft) of length, is the heart of the process. Hanging in the shackles, broilers pass through the Stork Water Bath Stunner, which delivers an effective, reliable electrical stun.
After killing and bleeding out, products are conveyed to the Stork Scalder. This immersion scalder has low energy and water consumption, a big benefit in African conditions.
Products are then thoroughly defeathered in the Stork Plucker, after which the Stork Head Puller does automatically what is a hard manual job.
Still hanging from the overhead conveyor system, products automatically enter the evisceration department. This ensures an ergonomic operating environment for workers, who do all cutting and drawing operations by hand, using a manual vent gun, opening scissors and evisceration forks. Hearts, livers, gizzards and necks are also harvested manually, after which a lung suction gun is used to remove the lungs. Each product is cleaned by a Stork Outside Washer before it passes the Leg Cutter which cuts off the feet, dropping the whole products into the screw chiller.
Products are cut-up manually using the Stork MC-300 Portion Cutter. Aglow Farms produces thighs, wings, breasts and legs. “We have gone into cut-up because in our market, not too many people can afford a whole chicken. It’s too expensive and too much for them. Chicken cuts are therefore becoming increasingly important here; we want to offer our clients the complete range,” continues Kofi Brobbey Kyei. “We are aiming to cut 80-90% of our production. In Ghana there’s a big market for thighs and wings and we want to open up the niche market for breasts. We’re targeting those intermediate distributors who until now have been importing products. We are trying to convince them to buy and sell products grown at home. They have all shown great interest in doing so and we are eager to see the results.”