LLC Poultry Factory Akashevskaya

05 Aug 2014

Poultry Factory Akashevskaya, Mari-El

In March of this year, Poultry integrator LLC Poultry Factory Akashevskaya started up their brand new 9,000 bph / 150 bpm greenfield poultry processing plant in Kuzhener, Mari El Republic in the Volga Federal District. The opening was conducted by the head of the Mari El Republic, Mr. Leonid Igorevich Markelov, in the presence of many local and foreign guests. Soon a second Akashevskaya greenfield plant, with a capacity of 6,000 bph / 100 bpm will be commissioned as well. Marel Stork was selected to provide both plants with completely integrated state-of-the-art poultry processing technology.

It is Akashevskaya’s policy to control and constantly improve their whole production chain. From grandparent stock control, incubation and rearing of broilers in the growing sheds, up to slaughtering, secondary processing and rendering facilities: al steps are being updated.

Poultry Factory Akashevskaya, Mari-El

The latest improvement projects include two poultry processing plants in Kuzhener and Jubilejnyj. They are another boost to the agro-economic development of the region. Both projects focus on improving product quality and raise Akashevskaya’s production capacity to over 200,000 tons per year. To enable that processes had to be redesigned and the level of automation became higher.
The design of the processes and construction is now according to the latest Western European standards.

First heart Lung Harvester in Russia

The 9,000 bph /150 bpm plant houses the first Stork Heart Lung Harvester (HLH) in Russia. The HLH is the latest addition to the selection of unique automatic giblet harvesting machines from the Nuova range. It separates esophagus and gizzard from the heart and lungs without the use of blades.

Downflow Plus chilling system

The chilling line is equipped with the latest version of the Downflow “Plus” chilling technology important aspect in enabling the production of top quality fresh products.

Cut-up and deboning

The cut-up is automated with a Stork ACM-NT processing line. The flexible, modular processing line enables the Company to produce a wide variety of fresh, high yield cut-up products. The produced breast caps are deboned with the Stork AMF-BX FlexControl system.
Legs are deboned automatically with the unique Stork inline ACM-MX leg deboning system. The automation of the cut-up and deboning operations leads to higher efficiency and an improved product quality and flow.

Automatic fixed-weight batching

In the secondary processing, fresh products are being batched automatically with Marel Multihead Weighers Fresh Poultry. These screw-fed automatic batchers have been specially developed for problem-free processing of sticky fresh products and ensure minimal giveaway.

Labeling and packing

The installed Marel Weigh Price Labelers make for labeling without worries. This customized Marel system realizes the requested fixed-weight solutions for all products and byproducts that are processed. Multiple jobs can be run at the same time.

Overall control

With the growth and higher level of complexity and automation, the need for overall production planning, monitoring and tracking and tracing of products and product flows became evident.
Akashevskaya opted for the integrated software solution of PDS-NT in-line production control and Innova overall data collection and control. Now full data integration enables complete order processing, tracking and tracing and real time insight in the various processing steps.

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The new processing plants focus on the production of a wide variety of top-class fresh poultry products. Products find their way to various markets via various outlets. Besides focusing on local and national markets, Akashevskaya exports products to various markets like the Emirates and Africa. With this expansion in poultry production capacity, the Volga Federal District and especially Mari El is becoming more important for Russian poultry production. In addition to Belgorodskaya Oblast, a new poultry production center in the Russian Federation is being established. With the completion of yet another successful integrated project Marel Stork is proud to support this next step in the agro-economic development of the region.

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