FRANZ-JOSEF ROTHKÖTTER: "LARGENESS OF SCALE IS NOT AN OBJECTIVE" SOFTWARE SOLUTIONS 10
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NOVEMBER 2013 Franz-JoSef Rothkötter: “Largeness of scale is not an objective” Software solutions > 10 Customer cases from all over the world IRIS widens its FOCUS > 4
Innovation – the road to success
CONTENTS
3 Stork In-line immersion chilling
“We as a Company are
convinced that offering
4 IRIS widens its focus
innovative solutions is essential
Highest yields within EU stunning if we are to be able to keep on
legislation
giving our customers the best
5 Esbro: first 13,500 bph (225 bpm)
possible support.”
greenfield plant in the Netherlands
a success
6 Safir
A Romanian poultry processing gem
Over the past three years the global poultry of significant improvements in giblet yields, productivity
7 Myronivsky Hliboproduct industry has made considerable investments in and product quality.
Stork technology supports Ukrainian expanding and modernizing its machine park.
agricultural giant We at Marel Stork Poultry Processing are proud With the number of Marel Stork solutions growing all the
that Marel Stork solutions have been chosen time, we are well aware of our responsibility for providing
for an increasing number of these investments. the best possible service. Besides optimum yields and
8 Emsland Frischgeflügel We have been able to implement a really production security, our preventive maintenance
“Largeness of scale is not an impressive number of green field projects in programs offer predictable maintenance costs.
objective; quality is!” almost all parts of the World including China,
Meanwhile we continue to invest in our service
South Korea, the Russian Federation and
organization. We are expanding our international service
10 Software and what it brings the
various European countries.
activities still further, all the while training our staff to
Poultry Processor bring their knowledge and skills to the level that you have
Recently launched new technologies are one of the most come to expect from us. We are also developing upgrade
important reasons why concerns are increasingly choosing kits for existing equipment. By doing this, we offer our
11 Severnaya Marel Stork as their supplier of processing technology. customers the possibility of making optimal long-term
latest improvement project A good example is Esbro’s brand-new poultry processing use of the latest technology without having to invest in
A boost in quality and capacity plant in the Netherlands, where the Stork AeroScalder is completely new machines.
among other items of Marel Stork equipment to inspire
the plant’s many visitors. The production and consumption of poultry meat
12 Objectives Achieved: worldwide is set to keep on increasing. Our leading
Production doubled We as a Company are convinced that offering innovative position in this growing market puts us in a good position
solutions is essential if we are to be able to keep on giving to develop even better products and services, which
our customers the best possible support in achieving their will allow you to continue to perfect your process and
13 Visibility through the windshield objectives. Examples, already in operation in many plants, the quality of your products.
rather than the rear view mirror are the innovative new FIM-20 RotoVac final inspection
machine, which gives an even cleaner product, and the I would like to take this opportunity of inviting you to
Wing Tipper HD, which has reduced the amount of rework. VIV Europe 2014 where, as you would expect, we will be
14 Increasing production Our new in-line weigher, SmartWeigher, is getting a lot of presenting a number of innovative new products, which
while keeping the footprint small praise for its ability to weigh more accurately at higher line will add value to the various parts of your process.
speeds, all this without products having to be removed
from the shackle and with calibration no longer necessary. Finally, I would like to thank you for the confidence you
15 Real time control have shown in us and look forward to further contact and
for maximum return We are proud of a number of Stork “classics” and are happy to working together with you even more closely, both
to give the Nuova evisceration system as an example. now and in the near future. I wish you a pleasant read.
This system is being successfully integrated into more
16 IPPE 2014: and more competitive processing lines. Customers who Arie Tulp, Sales and Marketing Director
Innovation through partnership have taken this step are unanimous in their confirmation Marel Stork Poultry Processing
2
Customer Insight
Stork In-line
immersion chilling
For 2 Sisters Storteboom Putten
plant the situation was clear.
Over recent years average broiler More information on the Stork
weights had increased but the
building did not allow the chill
In-line immersion chill system
tunnel to be extended. Product
core temperature was fine; the The Marel Stork in-line immersion chill system
tunnel was, however, almost makes use of water’s ability to chill products
always running at maximum up to 50% more quickly than air at the very
beginning of the chill process when the
capacity. More capacity was
product is still warm. A Stork In-line
needed to improve the chilling
immersion chill system is meant for systems
process still further. With the
with a rigid shackle.
evisceration department already
updated – including a new Stork
Products are transferred automatically to the
Nuova evisceration line – the
chill line overhead conveyor which transports
moment had come to install a them through the two phase chilling process.
Stork In-line immersion chill line. Before entering the air chiller they pass
through the immersion chill system where
The biggest benefits of the system? they are completely immersed. This cools
Arno Dekkers, Operational Director of them down rapidly. Dwell time in the
2 Sisters Storteboom, explains: “Besides immersion chill phase will depend on each
having more chill capacity which also individual situation.
uses less energy, our products are
microbiologically better than before”. Typical applications
The 2 Sisters Storteboom situation, as
Other advantages described above, is a typical application
Erik Zaaijer, Operations Manager of the where there was no space to extend an
primary processing division, takes up the existing air chiller to take account of heavier
story: “With its electrically adjustable bird weights, increased hourly capacities
valves, the system can be adjusted quickly From left to right: Erik Zaaijer – or both. In most cases the immersion chill
and efficiently. It is also very easy to clean. Operations Manager 2 Sisters system requires no additional floor space
You can get everywhere with your Storteboom. Sander de Bruijn – and can be installed under the overhead
cleaning lance. Another important point Area Sales Manager Marel Stork, conveyor system in the air chill tunnel.
is excellent product guiding. Products Arno Dekkers – Operational Director
stay nicely under water and do not come of 2 Sisters Storteboom. Another application is an existing two phase
out of the rigid shackle.” chilling system where the immersion phase
is done in a conventional counterflow screw
Partnership from the very beginning chiller. In this situation products are re-hung
Right from the quotation stage, the manually from the screw chiller to the air
Advantages of a Stork in-line immersion chill system
2 Sisters Storteboom team worked closely chilling line. With the screw chiller replaced
at a glance:
together with Marel Stork. Arno Dekkers by the new in-line immersion chill system,
explains: “We are always looking for the installation of an automatic re-hanger
partnership; our aim is the best possible between evisceration and chill lines becomes
cooperation. Everything was properly • Fast initial chill • Shorter processing time possible. This saves re-hanging labor and
prepared for this project, too. Together •G
ood microbiological • Controllable process allows products to be tracked and traced
we came to an optimal layout. After some through the process.
preparation work, we installed, tested quality • Low energy consumption
and started up the immersion chill line •R
eaches desired breast core •A
utomatic level control
over a single weekend. Everything went Stork In-line immersion chill system.
very well, precisely according to plan. temperatures and adjustable overflow
• T raceability and optimized • Small footprint
This is just what we are used to from
Marel Stork; knowledgeable people and logistic control possible •A
ttractive cost of ownership
impeccable execution according •A
ttractive yield, color and • Optimal cleanability
to plan.”
visual appearance
GO TO:
storteboom.com
3
IRIS widens
its F CUS
Last year Marel Stork launched Now the back of the product too portions as well as the front. This feature And that’s not all!
IRIS, an all-new Intelligent, Using a second identical camera, IRIS will will appeal particularly to processors At its launch last year IRIS was available
Reporting and Inspection System, now also assess the back of the product, using their ACM-NT cut-up system to for whole product selection lines only.
incorporating the very latest in which, like the front, it splits into seven assemble “A” grade leg portions The system can now also be installed in
image capture and data anatomic portions. automatically into fixed weight packs. the ACM-NT cut-up system. One
processing techniques. Since then With this camera, IRIS is able to pick up interesting application is where an
the system has been installed at a scratches on the back in such detail that No longer will portions with “hidden” ACM-NT cut-up system also serves as a
number of plants, where its processors can now program the defects on their back side find their way whole product selection line and is used
performance in the whole product maximum length of scratch acceptable into these packs resulting in unwelcome to identify and release products for sale
for an “A” grade product. The system will additional labor to identify and replace whole. The last year has seen IRIS being
selection line has more than lived
also pick up “red” tails. them. Downgraded leg portions will be put to work assessing products of a
up to expectations. Users have
Both features will be of particular value to kept separate at all times. different color or shape such as “corn fed”,
been impressed with the system’s
processors for whom grading the whole “organic” and “free range”. The system
consistently accurate grading and Flexible programming
product correctly is important. By using performs just as well on these as on more
with its user-friendliness.
two cameras, IRIS can now accurately An IRIS system with two cameras for the standard broilers.
Once installed, IRIS will run for
assess both the front and the back of each all-round assessment of each product gives
very long periods without product, thereby avoiding both misgrades its user unparalleled flexibility. Different Consistently accurate, quick to install and
maintenance and recalibration. and costly unnecessary downgrades. downgrade parameters can be set for the easy to live with, IRIS is an automatic
front and back side of each anatomic quality grading system which inspires full
Marel Stork development engineers More accurate leg grading portion. An example is the size of bruise confidence day in day out. Its additional
have not rested on their laurels but Being able to assess the back of the requiring the portion to be downgraded. new features make it more attractive still!
have been busy adding worthwhile product has advantages in the cut-up IRIS can be fully integrated into Marel
new applications to this proven department too. IRIS can now detect Stork’s plant-wide PDS-NT / Innova GO TO:
technology. defects and bruising on the back of leg management and control system. marel.com/iris
Highest yields Marel Stork Poultry Processing will unveil
a new high-frequency Water Bath Stunner
within EU stunning In its new high-frequency Water Bath Stunner Marel Stork combines
solid scientific knowledge of stunning with innovative engineering.
legislation
Highest yields and improved meat quality, setting new standards for
electrical stunning, are what you will be able to expect from the new
solution.
Within the guidelines laid down by the EU legislation, the new stunner allows
poultry processors to strike just the right balance between stunning efficiency and
meat quality. The new Stork Water Bath Stunner has an extended frequency range
and will put poultry processors firmly in control.
In 2013, EU Council Regulation 1099/2009 on the protection of animals at the time
of killing became applicable in all member states of the European Union. The new
regulation aims to improve animal welfare and sets common standards across the
European Union. It takes account of technical advances made in recent years.
Requirements for electrical water bath stunning have been tightened and are
set out in greater detail. The Regulation dictates substantially higher electrical
values for water bath stunners, lays down specific requirements for their design
and operation and specifies new guidelines for laying out the kill line.
The new high-frequency Water Bath Stunner, which complies fully with EU
legislation, is coming soon.
4
Customer Insight
ESBRO: first 13,500 bph (225 bpm) greenfield
plant in the Netherlands a success
With the initial post-
commissioning phase over, Arie Tulp – Sales and Marketing Director Marel Stork (l).
Esbro Wehl is now processing Joop Eskes – Owner Esbro (r).
some 120,000 broilers daily.
According to owner Joop Eskes,
the line is running well and
smoothly. In spite of normal
start-up problems and now that
his staff have become used to the
new factory, he is very satisfied.
Eskes says: “Now we have space
and a relaxed atmosphere. The
working environment is pleasant
and our people are satisfied.
We now calculate everything
precisely but for me it’s already
clear. The epidermis after
scalding is much better than
before, giblet harvesting is top,
yields are higher and our decision
to go for three cut-up lines was
a good one. We are processing
more broilers, quality is better
and costs per kilo of product are
down.” This is what a satisfied
and justifiably proud Joop Eskes
says about his new Esbro, the
realization of his dreams.
work; clean surroundings, clean and dirty Working together is essential Marel Stork as technology partner
areas strictly separate, short walking Eskes mentions how important working “For us Marel Stork plays an important
It’s a pity that his parents have never seen distances, the colors and sufficient space together is for the industry as a whole. part in the mix. Together we have
the new Esbro. That’s what Eskes always to be prepared for the future. Sometimes He sees keeping the consumer a fan of implemented a total concept. This
says when you ask him what he is proud it’s also a bother having to get involved in meat as a challenge facing the whole includes many of the best new solutions.
of: “That I am able to continue my parents’ everything. It doesn’t make life easy. sector. “Sometimes meat is not so sexy Take for example the AeroScalder.
thought process in this way. When I arrive A lot has happened and we have done it. anymore but I feel that we should be After scalding we see a clearly cleaner
at the plant, one thought always comes to I have to give the lead and stick my neck proud of our agriculture and our sector. product, a product where the epidermis
mind: look what we’ve achieved. From the out. We have taken a huge step forward We can only tell it as it is. I don’t think our is first class, better than before. We will
shed in the back garden via Doetinchem and are going to take many more. Within broilers have a bad life and we process continue to optimize and innovate.
to all of this. These are really huge steps. a year we will grow to a production of them correctly and well. Our equipment is We have the space, the experience in
From the time I was fifteen years old, some 135,000 broilers daily”. set up for this. It is an efficient well-oiled practice, the right knowledge and
during holidays I was always working system where we strive every day to do expertise and the right people with
with chicken. I don’t know anything else. Challenges enough our best, hitting the right balance the right attitude.
Now we are here. I also think a lot about Eskes thinks that the Netherlands has a between animal welfare, product quality
my employees, how all together we hard time as an exporter. As far as he is and process efficiency while respecting Together we can do great things;
buckled down to it. My compliments concerned the only correct answer to this our broilers”. of that I am convinced”.
to them!” is to go for it, keep on optimizing and take Above all, Eskes sees the advantages of
care to produce a top-quality product at the Dutch way of doing things: “In the
Involved an acceptable cost. Eskes wants to do Netherlands, we are not vertically
Eskes takes us round his spotless premises. this first by creating healthy volumes integrated. Each link wants to add
From the flower arrangements which and then developing further activities something to the value chain and we are
decorate the reception area, the chairs in from this. Eskes says: “I am thinking here all entrepreneurs. For me that means that
the canteen, to the open layout with a lot of doing tray packing and de-boning I want to supply top-quality both as far
of glass, Eskes and his wife have left their ourselves. We have the room and as product and process are concerned.
mark everywhere. Joop himself had a large possibilities. I see the new plant as the In the Netherlands we are never going
say in determining how the processing start of a new phase, where we as a to win on price alone. We work hard but
plant should be laid out and equipped. business have to grasp new opportunities we must go for high yields, efficiency
Eskes continues: “I want everything to and create them for ourselves.” and innovation. Innovating is a must”.
“With the AeroScalder
the epidermis after
scalding is much
better than before.”
The infeed of the AeroScalder.
5
Customer Insight
Safir
A Romanian
poultry
processing gem
George Safir – Executive Director Safir (l),
Ruud Berkers – Area Sales Manager
Marel Stork (r).
With its latest investments Safir, that are particularly important to us such time, it became clear that this smooth Partnership for further growth
a poultry processing company as quality, honesty and partnership.” running combination had lifted cut-up Safir has become a highly respected in
based in Vaslui in Romania, has yields by several percentages. The process the Romanian poultry processing market.
added some more pages to its Quality in all aspects is cleaner and requires less maintenance. Their cooperation with Marel Stork is
history book. These investments When it comes to improving quality, Safir Because an overhead conveyor is now based on the mutual goal to keep on
are the very first SmartWeigher focuses on several aspects. The Company used, there is more free floor space. The developing. “We think Marel Stork
and Weigh Price Labeler 9000 strives to make the best possible working environment has become more offers the best quality machines, says
series to have been bought by high-quality products and make them pleasant and we have room for possible Mr. Iulian Safir, Technical Director, “The
the market. The new Marel Stork affordable for the local market. Mr. Safir future developments. Mr. Safir continues: design and the attention paid to detail is,
strongly believes that only the best “In this building our hourly production from an engineer’s perspective, very
equipment is part of the latest
machines and a smooth running capacity can’t grow, so we needed to good: some machines are a real jewel of
phase in Safir’s update program.
production process can make that possible. focus on efficiency and improving the technology. What is important to us is
Yields are now higher, processes
He says: “Over the last 7 years we have process. We clearly succeeded.” that the engineers have a high level of
have been improved and
updated virtually our whole plant. knowledge and a lot of experience.
production increased. Social responsibility
We have a tradition of innovating. In 2006 We believe in their skills and they are
the kill and EV lines were replaced. We Operators are happy with the new work very supportive. The installation and
George Safir, Executive Director, has a were the first company in Romania to buy stations and like the more spacious commissioning of the SmartWeigher
clear vision: “If you don’t develop, if you the Nuova EV system. We made the choice environment. Safir explains: “For us the and the ACM-NT cut-up line went very
do not improve, your company eventually for top-quality evisceration and high yields. quality and drive of our staff are essential. well. We have never had a breakdown or
dies. Since Safir started in 1991, we have If you look at the return on investment, They allow Safir to perform well, to make problem with our Marel Stork machines.”
consistently invested in the expansion it is clear that we made the right choice. the good products we make. Most of
and diversification of our company. It We strongly believe that by continuously them are from the local community. GO TO:
started with the acquisition of a feed mill. investing in our plant we have reduced We try to be a good employer. So I feel safir.ro
Over the years we have grown strongly total cost of ownership and now have strongly that it is more than fair to give
and have updated several parts of our higher quality end products.” something back to the community. One
operation. Right now we are an of the ways we do this is by encouraging
integrated company that controls the The latest improvements and sponsoring sport. It’s healthy and
whole value chain. Marel Stork is our Together the SmartWeigher and ACM-NT fits in perfectly with our vision that our
supplier for poultry processing make up a combined automatic selection poultry products provide consumers with
equipment. In them we recognize values and cut-up line. After a short period of a healthy basis.”
In Romania Safir products are known under the brand ‘Deliciosul de Vaslui’ (Delicious
from Vaslui). Safir’s wide range of products is particularly well-known in the surrounding
area, with outlets only selling Safir products. Safir also sells its products nationally via
retail chains, the food service industry and distributors. Quality standards are high and
Safir can export their products to the EU.
The Company’s processes and products are under the permanent control of the
sanitary-veterinary and environmental authorities and conform fully to European
standards.
6
Customer Insight
Myronivsky
Hliboproduct
Stork technology
supports Ukrainian
agricultural giant
The new Vinnytsia poultry facility, as well as a poultry processing plant ‘Nasha Riaba’ trademark More on MHP
one of the latest projects done by featuring two 11,500 bph (191 bpm) lines MHP management believes that Myronivsky Hliboproduct (MHP) is the
Myronivsky Hliboproduct (MHP), provided by Marel Stork. consumers are an important driver. The largest agricultural company in the
is a world-class poultry complex, The complete Greenfield project houses Ukrainian consumer is moving to food Ukraine and generates 50 percent of the
located near the town of Ladyzhyn the latest in poultry processing which is healthier, of higher quality and Ukrainian industrial production of chicken
in the Vinnytsia Region (Ukraine). technology and includes kill, evisceration which offers convenience. It goes without meat. Besides focusing on the production
When the facility reaches full and selection lines feeding three saying that poultry meat fits in perfectly of chicken meat, the company also grows
capacity in 2017-18, it will be one automatic cut up lines. Solutions for with that trend. Marel Stork offers a wide grains, sunflower and corn on some
of the biggest poultry complexes automatic batching, freezing and range of equipment that enables the 360,000 hectares of land.
packing have also been put in place. production of all possible products.
in the world, with a capacity of
MHP exports to more than 25 countries,
approximately 440,000 tons of
Top technology for top products Oleksiy Shevchenko, Plant Manager of including the CIS-countries
poultry meat per year. In 2014,
Yuriy Kosyuk, Chief Executive Officer of the poultry processing facility, comments (Commonwealth of Independent States),
the poultry farm’s ‘phase one’ will
MHP, says: “Our group is completely on the products: “For those wanting to the Middle East, Central Asia and several
reach its full annual production
integrated and we control each give their families only the very best, the African countries. With permission to
capacity of 220,000 tons. The
production stage, from growing grains ‘Nasha Riaba’ trademark is the golden export to the EU, the company sees
whole complex has been realized on the field to the end products on the standard for poultry meat purity and plenty of opportunities for successful
with mainly Dutch technology, store’s shelves. We guarantee consumers health. Poultry products are distributed further expansion by the end of this year.
including Marel Stork Poultry that all our products meet the highest by refrigerated trucks at tightly controlled Yuriy Kosyuk, Chief Executive Officer of
Processing. international standards for quality and temperatures, so consumers receive fresh MHP, says: “This is a logical step towards
safety. We choose to cooperate with the goods of the highest quality. In our ‘Nasha implementing our strategy of growing
The scale of the Vinnytsia poultry complex companies offering the best possible Riaba’ shops, consumers can buy poultry export sales and diversifying
is remarkable: a total of 24 rearing zones technological solutions for reaching these meat, convenience food and other meat geographically. We are ready to provide
with 38 poultry houses each, a dedicated, high standards. We knew that Marel Stork products. Other important channels are European consumers with tasty, high-
on-site feed plant, hatcheries that meet would enable us to produce the very best retail organizations like ‘Auchan’, ‘Metro’ quality meat and poultry products.”
100 percent of the plant’s internal needs, fresh poultry products our markets want.” and ‘Novus’.”
Upgrading again
MHP will soon upscale their production
capacity. The two 11,500 bph (191 bpm)
lines will be upgraded to 13,500 bph
(225 bpm) each. The new high-speed lines
are becoming more and more common
practice. They enable processors to further
optimize their processes and reduce their
production costs per kilo of end product.
GO TO:
mhp.com.ua
7
Customer Insight
Emsland Frischgeflügel
The Cellerland plant.
“In our cooperation with Marel we give one another space
and we challenge each other to take that extra step.”
“We have chosen to make the best revamped for the higher capacity. better working conditions than in many Necessary innovation
possible quality fresh products. At this moment the Emsland group comparable concerns. It is a question of New end products demand new
Visually, microbiologically and produces some 300,000 tons of poultry give and take. We expect a lot, but also technologies. Marel Stork is always aiming
as far as taste and nutritional meat per year or approximately give something back to our employees, to translate the latest developments in
value are concerned they really 3.2 million broilers per week. often in the form of various facilities. the market into integrated solutions for
are top class. That is why we are We have opened a crèche directly next to processing at high throughputs. The
‘Largeness of scale is not an objective’ the Emsland plants where our employees’ various portioning solutions are a good
continually perfecting our
processes. Efficiency and Franz-Josef Rothkötter notes: “Producing children are well looked after while their example of this. The I-Cut cuts breast
effectiveness, everything must be on a large scale as we do means that you parents work. Quality means commitment fillets into fixed weight strips or fillets at
can optimize your process at a relatively and dedication on the basis of mutual very high speeds with a high degree of
seen in the light of the quality of
low cost per kilogram and in such a way respect”. accuracy and with minimum give-away.
our end products”. According to
that animal welfare is looked after at least Rothkötter: “The various Marel Stork
CEO Franz-Josef Rothkötter, Focus on the customer
as well and in some aspects better than solutions we have such as the I-Cuts work
keeping a sharp focus and a clear
before. This is what the market expects. “Above all, we as a company must ensure perfectly. But with all our various end
strategy are the basis for the
A big and very important advantage is a good relationship with the market, that products we still move them around too
success of Emsland Frischgeflügel. much. Our ultimate goal is to have
that per product we use much less water, we can offer the right products at the
“I am convinced that you can only electricity, energy and raw materials. right price”. Rothkötter explains: everything in line. We can still increase
achieve the best if you process Largeness of scale is not an objective as “We always keep a sharp focus on our efficiency here. This is one of the
poultry on a large scale with the such. Combined, however, with our aim products and, therefore, on the market, challenges we are working on with
right people and do this with the for sustainability it becomes added value on our customer. We equip everything Marel Stork”.
very latest technology. This is the for us and our customers. as best we can for a good fresh product.
best for product quality and also “Better” always takes precedence over Optimizing within the chain
for being able to produce By perfecting the process, installing a “cheap”. We concentrate deliberately on One thing is clear! Emsland stands for
sustainably”. completely measurable process and by large quantities of a relatively narrow perfection, whether we are talking about
using the latest process technologies, range of end products. product quality, the efficiency of the
Increase production over the years we have been making We are a good fit with our customers – primary process or even the internals of
Emsland was in at the start with various ever better use of our input material, mostly large retailers – and they the production chain itself.
developments in the poultry processing the broiler. In my opinion, that is also with us”.
industry. A good example is processing at important for producing in a truly Some time ago Emsland and Marel Stork
the highest possible production capacity. corporately responsible way”. “You can see how what we offer has commissioned the first complete feet
The first 13,500 bph (225 bpm) line was grown enormously in recent years and processing system. Richard Wenneker,
developed together with Marel Stork for Focus on staff we do of course follow trends in the Factory Manager of Emsland 1 & 2,
the Emsland 2 factory in Haren, Germany. For Emsland it is clear that taking the care marketplace. Since cut-up has become explains: “The system works well in
Based on positive experience at Haren, to produce a good product is also very ever more important, we are seeing more practice but needs further development.
Cellerland, the latest new plant near much in the hands of good staff. “We look added value, more and more seasonal We are now busy looking into the chain
Wietze, was fully equipped for this high after our people well. More than 80% of products (for the BBQ for example) to see how we can improve the quality
throughput. It is now common our employees are on fixed contracts. convenience products, marinated, of our end products still further”.
knowledge that Emsland 1 will also be They are rewarded with considerably cut and ready-to-cook products”. Mr. Rothkötter adds: “If for example we
8
“Largeness of scale is not an objective; quality is!”
Stork TrayTrack.
change the composition of our feed, this meantime. Mutual trust, transparency
can influence feet quality and with it the and belief in the power of continuing
yield and ultimately the ROI of the whole innovation and improvement are
feet processing system”. characteristics of the relationship
between Marel Stork and Emsland.
TrayTrack: Rothkötter comments: “We can only grow
logistical impact with payback by constantly improving on all fronts.
TrayTrack is another example of a project We optimize everything as far as possible.
in the framework of optimizing the By continually measuring and working
process. This system is completely through all our figures we know where
automated and uses automatic loading we have room for improvement, focusing
stations, overhead conveyors and release on our overriding objective of supplying
stations to bring different trays filled with a better end product at as low a cost as
product to exactly the right packing possible. The relationship with Marel
machine. For Emsland, the system means Stork at both a business and a personal
an improvement in in-house end product level is really good. The bond between
logistics, mainly saving a lot of manual the two concerns is a strong one. In our
work. Christian Borker, Factory Manager cooperation with Marel we give one
of the Cellarland plant, adds his another space and we challenge each
comments: “The system also has an other to take that extra step. This is good
automatic buffer function. If we have a for both parties and keeps us focused.
short stop, changing sticker rolls for Striving to make a top-quality product
example, or if there is a small fault, the and focusing on continuous improvement
trays with product on them continue to and innovation is an essential feature
circulate without it being necessary to which bonds both concerns together.
call on staff for help ad hoc. The system It is a key to success.”
works well and here too we are working
together with Marel Stork on improving GO TO:
the system”. landgefluegel.de
1+1=3
Since the start of Emsland 1 less than ten
years ago, Marel Stork has been the main
supplier for all three factories. Emsland
Frischgeflügel has become the global From left to right: Christian Borker – Factory Manager of the Cellarland plant,
reference plant and many visits from Franz-Josef Rothkötter – CEO, Richard Wenneker – Factory Manager of Emsland 1 & 2.
colleagues from the industry have made
the Company world-famous in the
9
Software and what it brings
the poultry
processor
IT and software are transforming hygiene. Together, good plant layout and
poultry processing, helping Innova/PDS-NT software ensure that the
processors face the many right product is brought to the right
challenges coming from the downstream process in the right volumes,
market and run their plants as making the best use of people and
efficiently and profitably as machines.
possible. Under the Innova/
PDS-NT umbrella, Marel Stork The vital role of software can be seen
offers a modular package of clearly in the cut-up and de-boning
department. It can be used, for example,
software solutions to help
to control the feed of cut legs and breasts
processors, large and small,
to automatic de-boning systems, so that
optimize the production value
these systems are always fed with product
chain from receipt of the live bird
of the right weight at the right tempo.
right through to dispatch of the
Two recently developed modules add
end product.
further sophistication.
Several key areas of interest to production The combined rate limiting module
and technical management are: allows a single downstream process to be
fed with the correct raw material at a fixed
Controllable yield management tempo from two or more distribution or
Optimizing yield and throughput is the cut-up lines. The floating range control
most important task faced by any module is typically used to distribute
production manager. To do this, however, sized breasts over two or more de-boning
he must have the right information. systems. The borders between the sizes
“float” automatically ensuring that each
Marel Stork offers a fully in-line process, filleting system is kept fully supplied with
where product can be automatically appropriately sized breasts at all times.
counted, weighed and graded at various
key points. Innova/PDS-NT software Production control
presents all weight, count and quality For top performance, equipment must be
data in real-time, highlighting any set correctly. Plant floor management “Getting the most out of equipment can really make
variance from plant determined KPIs must be able to monitor it on a
(key performance indicators). continuous basis. Any variance from a KPI all the difference to yields and profitability.
is then seen immediately and appropriate That is why control systems such as Innova/PDS-NT
Yield management means ensuring action can be taken.
the most profitable use is made of are becoming ever more important.”
raw material. A number of systems now feature menu
Using weight and quality data captured control, where operators enter product
from vision systems and in-line weighing parameters and software and electronics
systems installed at the end of the then set the equipment correctly. One
primary process, Innova/PDS-NT software example is setting of the GP live bird Uptime and cost of ownership processing, inventory control, dispatch
automatically allocates the right product handling system, where the smooth flow An efficient, cost-effective process means and interfacing with ERP systems.
to the right downstream process. It of product from container to hang-on is minimal downtime. Much equipment now The Innova/PDS-NT umbrella can
matches production to customer orders guaranteed regardless of bird weight and features automatic fault tracing. Technical therefore cover your whole plant; its
as efficiently as possible. The higher the the number of birds per container tier. staff no longer have to waste time looking modular set-up allows you to build the
volumes handled and the more complex Another is the latest AMF-BX FlexControl for the reason for line stoppages. system at your own pace.
a processing plant, the greater the need breast cap filleters, where all modules are
for this invaluable help. reset automatically when a new cap Doing preventive maintenance also Making the difference
weight is typed into the system. lowers the risk of downtime. Equipment Getting the most out of equipment can
Yield management also means keeping monitoring software stores data on really make all the difference to yields
costly give-away to a minimum. Batching Enhanced food safety alarms and other events collected from and profitability.
product into standard weight packs is an Food safety and full traceability are PLCs and switchboxes and presents this
activity, which will cost money if not done today’s hot issues. real-time in a web-based environment. That is why control systems such as
properly. Innova/PDS-NT uses clever With a fully in-line process, the Innova/ The combination of automatic equipment Innova/PDS-NT are becoming ever more
algorithms to batch automatically with PDS-NT automatic tracking and tracing monitoring, skilled Marel Stork engineers, important. Innova/PDS-NT software has
minimal give-away. system will follow each product right customized training packages and a 24/7 been developed in-house to add value to
through the processing plant. If there is help desk give plants the tools to maximize Marel Stork processing equipment and is
Smart product flow a complaint, plant management can uptime and minimize cost of ownership. based on many years of experience in
Product should flow smartly through the retrieve immediately when the faulty processing poultry worldwide.
process to the chilling department with product was processed and whether Plant-wide management
no buffers. This will optimize yield and vital systems were working correctly at There are also software modules available GO TO:
efficiency, save labor and improve the time. for activities such as sales order marel.com/innova
10Customer Insight
Severnaya
latest improvement project
A boost in quality and capacity
The modern poultry integration flow no fewer than 80 growing sheds to say that coordination and planning of
OAO P / F Severnaya, acquired in were built, each for a capacity of 80,000 the project both in the Netherlands and
1996 by the Dutch Agro Invest broilers.” Russia, contributed to its success.
Brinky, lies just outside St Production capacity, product quality
Petersburg. The Company recently Big steps forward! and yields have all gone up.
made further substantial During the three-month project, the
“We have chosen for investment in the modernization entire GP live bird handling system was
updated for an optimum start to the
Jesse Bos: “We have chosen for Marel
Stork again because of the high-quality
and expansion of its production
Marel Stork again capacity. The fully vertically process. Kill and evisceration lines were technology and high yields. And, just as
then expanded with new modules and important, the Stork people. They are
because of the high- integrated company now provides
updated to the latest standard. The Stork very committed and motivated,
the local market with the highest
quality technology and quality fresh poultry meat and
Nuova 24 eviscerator was installed. This indispensable for projects of this size,
saw an increase in giblet yields. especially in combination with the time
high yields. And, just as processes two million broilers per
pressure we had.”
week. The latest investment Chilling results
important, the Stork project was implemented in close More to come
The traditional spin chilling installation
people.” cooperation between the was replaced with a combination of Today Severnaya is a high-volume
Severnaya and Marel Stork teams in-line immersion chilling and in-line air processing plant equipped with the
Jesse Bos – Project Manager from Brinky. and was finalized in 3 months. chilling. This solution included automatic latest technology with its focus on the
Severnaya now has the latest re-hanging of the products and in production of high-quality fresh whole
technology and is ready for the addition to improving product quality products for the Russian market. With a
next challenge. now allows full traceability. Bos adds: “We weekly production of over 2,000,000
also saw a huge reduction in labor costs. broilers, the focus is shifting towards
“The first years after 1996 were used to Because of the limited space and need for more cut-up parts packed in their final
modernize existing facilities (feed mill, cost control we decided on a multi-layer retail packaging. Bos adds: “Market
hatchery, growing sheds and processing chilling tunnel. This meant that extensive requirements are changing and we are
plant). In 2001 two complete Stork lines reconstruction of the building was not already planning for the next
were purchased. Soon the various links in needed and our 27,000 products per hour improvements.”
the chain could no longer cope with the (450 bpm) could be chilled to the right
strong growth”, says Jesse Bos, Project breast core temperature in the required GO TO:
Manager from Brinky. In consultation with time.” brinky.com
Marel Stork the decision was taken to
expand both 9,000 bph (150 bpm) lines to Fast and well done
2 x 13,500 bph (225 bpm) lines, the Expansion, a very large project, has been
maximum capacity achievable today in successfully realized in three months with
the industry. Bos: “Alongside the increase a large team of employees both from
in processing capacity other companies Severnaya and Marel Stork working
in the group had to grow too. closely together. Any loss in production
An example: to enable a smooth product hours was kept to a minimum and it is fair
11Customer Insight
Objectives Production
Achieved: doubled
2 Sisters Storteboom in Zeewolde, “The Multihead Weigher led to a
the Netherlands, was looking for
a way to speed up the weighing measurable increase in food quality
and batching process for its fresh and safety – and happy customers!”
poultry lines. Marel’s Multihead
Weigher more than delivered: it Hans van Norden – Plant Manager 2 Sisters Storteboom Zeewolde.
doubled production speed while
maintaining maximum flexibility.
Manual weighing “Fitting it into the existing set-up was a
“Up until a year ago, weighing of our bit of a challenge here and there, but
fresh poultry products was largely done Marel Stork solved it perfectly,”
manually”, Zeewolde Plant Manager Van Norden says. “After weighing and
Hans van Norden explains. “Accuracy was batching, we can now run with two
pretty good, and it offered us a lot of different packing lines for our different
flexibility. But our packing and sealing types of products.” Van Norden
machines were only working at half is very happy with the weigher’s
speed. Obviously there was a lot of performance: “It’s perfect. We doubled
unused potential there and with sales production on the fresh poultry line.
growing, we really wanted to increase Accuracy also improved and as an extra
production.” bonus give-away is reduced by about 1%.
And it’s quite a sight, seeing a Marel
Many different products Multihead Weigher at work.”
The search was on for a solution that
would fit in the existing fresh poultry line Additional advantages
without losing flexibility. Van Norden said: Apart from doubling the speed and
“When we talk about fresh poultry, we maintaining flexibility, the Multihead
actually talk about a whole range of very Weigher offers additional advantages.
different poultry products: dices, filets, Van Norden explains: “All our fresh poultry
schnitzels, marinated or tumbled. An products go to the foodservice business,
automated solution would have to deal some of them very large fast food chains.
with all those products, and change-over To them food safety and hygiene are
between processes would have to be extremely important. With the Multihead
quick and easy.” Also the system would Weigher, products move much faster
have to be reliable, state-of-the art, through our plant, which means less
precise and fast. exposed products and better control of
temperature. This has led to a measurable
Testing increase in food quality and safety –
Van Norden and his colleagues and happy customers!”
approached different manufacturers,
but soon gravitated towards Marel Stork. 2 Sisters Storteboom
Van Norden: “We already have a history With eight production sites in the
of partnership and we know they provide Netherlands and one in Poland, 2 Sisters
quality equipment and good service”. Storteboom BV is one of the larger
A delegation of 2 Sisters Storteboom poultry processors in Europe. The
visited the Marel facility in Oss, where a Zeewolde facility opened in 2011 and
Multihead Weigher Fresh Poultry was set focuses on wholesale, retail and
up. Van Norden remembers: “For us, that foodservice. 2 Sisters Storteboom BV is
was perfect because we had some very part of the 2 Sisters Food Group Ltd,
specific demands regarding our products, based in the UK.
especially the marinated ones. We wanted
to be sure they wouldn’t get damaged or GO TO:
stick together. We did a lot of test runs storteboom.com
with our own products and the results
were very impressive. It convinced us that
Marel Stork was the right choice again.”
Running smoothly
In 2012 the Multihead Weigher was
delivered and set-up in Zeewolde.
12I N S I G HT – S TO R K P O U LT RY P R O C E S S I N G
Visibility through the windshield
rather than the rearview mirror
It’s the difference between being consistent line speeds (without The SmartWeigher’s precision guarantees in your downstream processes.”
in control of your process or your acceleration or deceleration) and without you deliver what you promise every time. Adding the SmartWeigher to your
process controlling you. The Stork transferring of product. existing system is simple due to the
SmartWeigher allows you to make According to Southerly, the team at OMP Customers who are currently operating machine’s versatility.
fact-based decisions that lead to is finding the SmartWeigher very easy to the SmartWeigher have consistently
full-time process management use, due to the one-time factory achieved single-digit gram accuracy It can either stand on a floor on legs or
for total process control. calibration. “After installation and two creating less rework. Less rework equals can be hung – opening up valuable floor
months of operation, we only check a labor savings for your bottom line. space for additional processes or
OMP Foods in Rogers, Arkansas, identified calibration once per week,” he explained. improved operations flow.
a need to efficiently size whole products “We can hit a very small window,”
(WOGs) for production and distribution. “There’s almost no preventive explained Curl. “Because your drops are “It has delivered what we were looking for
The key parameters that would determine maintenance that goes into the machine more accurate, you don’t have to worry – ease of use, efficiency and accuracy,”
success, according to Plant Manager – basically just a visual inspection of the about the wrong size products ending up said Southerly.
Scott R. Southerly, were ease of use, plastic pieces,” confirmed Sales Manager
efficiency and accuracy. After reviewing Dwight Curl. “This means very low cost
their available options, OMP chose the of ownership.”
Stork SmartWeigher for their operations
because it promised to deliver on every
count.
Little to no maintenance frees up your
skilled maintenance people to perform
other tasks. Accuracy brings a range of
NEW Stork SmartWeigher
Easy to use, efficient and accurate benefits to your operation.
The SmartWeigher is a line-driven, SmartWeigher’s proven success in cut up operations is now expanded for the use in
weighing module currently available for Precision equals higher value down distribution lines.
whole birds or back halves (whole the line SmartWeigher for distribution lines offers:
saddles) going into cut-up. The precision- Imagine, for instance, eliminating
based design of SmartWeigher allows for customer complaints about size. •H
igh performance for separation of light, average and heavy birds to control your
product flow into cut-up lines
• L ow maintenance and low COO
• N o daily calibration
• N o floor space needed
“SmartWeigher has delivered what we were • A ll in a robust and reliable machine
looking for – ease of use, efficiency and accuracy.” With the addition of SmartWeigher’s proven technology for use in distribution lines, we
will offer the perfect, universal solution for in-line weighing. Contact us to find out how
Scott R. Southerly – Manager OMP Foods. you can expand your distribution line accuracy with the new Stork SmartWeigher.
13Customer Insight
Increasing production
while keeping the footprint small
“Marel will definitely
play a role in future
expansions and
automation.”
Theo van Strijp –
Factory Manager at
Rainbow Farms (l),
Nico Gomes – Engineering
Manager at Rainbow Farms (r).
When Rainbow Farms, one of the as soon as these plans came onto the How does it work? “We have had the Marel Multihead
largest producers of poultry drawing board. This Multihead Weigher was developed Weighers for about a year now and are
products in South Africa, decided on the basis of many positive user very happy with them. They have made
to upgrade and increase their One of the main challenges in the project experiences with the Marel Multihead it easy for us to increase capacity using
throughput of poultry products, was floor space. The 16,000 kg (35,200 lbs) Weigher series. Robust, easy to use and the same floor space. They are highly
their choice fell on the well-known per hour being processed at the time designed for optimum throughput with accurate and easy to operate. We were
ACM-NT cut-up lines and the were being packed manually and there minimum giveaway, the Marel Multihead able not only to lower labor cost, but also
recently launched Marel was simply no space for more manual Weigher IQF Poultry handles poultry cuts increase volume and make our business
Multihead Weighers. packing lines to handle the planned at high capacity and with great accuracy. more flexible,” says Theo van Strijp,
increase to 22,000 kg (48,500 lbs) per It is designed for the rapid, accurate Factory Manager at Rainbow Farms.
hour. At that point, Marel Stork launched batching of frozen poultry products. The “Marel equipment has shown its
Over the years, Rainbow Farms has its newly developed Multihead Weigher unit’s 14 large hoppers, each with a reliability and will definitely play a role
equipped its processing facilities with a IQF Poultry. When these machines were capacity of 7 liter (1.54 gal) are specifically in future expansions and automation.”
range of Marel Stork equipment, such as drawn into the area, they only used an constructed to handle the toughness of
ACM cut-up lines, portioning machines estimated 50% of the original floor space frozen products at a high throughput of ACM-NT cut-up lines
and compact graders. So when Rainbow even when the additional 6,000 kg up to 60 batches/min. Another important factor in increasing
Farms was planning an increase in their (13, 200 lbs) of product was taken into processing capacity is the three new
production, Marel Stork became involved consideration. The Multihead Weigher IQF Poultry Stork ACM-NT cut-up lines. The ACM-NT’s
Marel Stork installed six Multihead were chosen, as they are very accurate,
Weighers IQF Poultry, which are now reliable and provide the company with a
batching 18t of products per hour. The high level of flexibility. Each line runs with
machines’ main task is to make up 2kg a different weight range – light, medium
(4.4 lbs) batches for mixed portion packs and heavy – resulting in the best possible
at 25 portions per minute at 3,000kg cuts without the need for frequent
(6,614 lbs) per unit. Batch weights can, blade adjustments which would
however, range from 1.15kg (2.5 lbs) to a interrupt production.
maximum of 5kg (11 lbs).
From the cut-up lines, products are
Even when producing 1.15kg (2.5 lbs) transported to the injection system,
bags at 50 bags per minute, accuracy and which is monitored by the Marel
giveaway are still well within the Injection Monitoring System (IMO).
customer’s specifications. Each Multi The IMO calculates the average weight
Head Weigher has spare capacity giving increase within a given timeframe,
production welcome flexibility in pack making it possible to adjust injection for
sizes should the need arise. maximum product yield.
Multihead Weigher for chicken liver The whole cut-up department has been
Two Marel Multihead Weighers Fresh extended and has new functionalities.
Poultry have also been installed at two The lines are controlled by the Stork
locations for batching fresh chicken liver. PDS-NT software. Production is now
This has greatly increased fixed weights much more flexible.
accuracy. The automated system can
produce these at up to 45 fixed
weight batches per minute of 250 g GO TO:
(8.8 fl oz) tubs. rainbowchickens.co.za
14I N S I G HT – S TO R K P O U LT RY P R O C E S S I N G
Real-time control
for maximum return
What is an additional 17,000 lbs It is custom fit to meet each customer’s explained. “It provides the plant with
(7,700 kg) per year per employee needs via a modular design offered in an traceability to an individual operator
in throughput and yield worth to eight-station initial set up, expandable by along with real-time feedback on the
your operation? two-station increments in both right- and system monitor and individual operator
left-handed stations. The ergonomic displays. The individual operator displays
design, low cost of ownership and have been simplified to have LED
With Marel Stork’s new StreamLine, results superior cleanability tick all the right indicators which rank the operator
such as this are consistently achievable. check boxes for today’s modern poultry incrementally against a set target.”
Results from a thigh deboning operation processor while providing ease of
returned an almost 2% yield improvement maintenance and flexibility. Capacities for the StreamLine are
versus a typical manual trimming dependent on the specific operation you
operation. The flexibility of the line leads to a higher are running. Looking at a typical thigh
quality end product by giving processors deboning process, based on 20 stations,
Yield, quality and throughput control the ability to maximize the selection of 240g thigh incoming weight and 10 pieces
– in real time cuts into highest price products and to per minute per operator, you can expect a
“The concept for the latest generation of minimize loss. Further customization is capacity of 2,857 kg (6,300 lbs) per hour or
our StreamLine system was simple,” noted easy through the choice of process and about 22,680 kg (50,000 lbs) per shift.
Todd Graff, Sales Support Manager for processor-specific preferences. These
Marel Stork, “improved pounds per options include: The Stork StreamLine is the perfect
man-hour. Streamline keeps a consistent replacement for your manual trim tables
flow of product in front of the operator (no • C
hoice of infeed hopper and conveyor by monitoring operator performance and
waiting for product) and, as the operator wn Conveyor
- O improving product quality. With the use
works, performance is monitored and the - Skinner of a StreamLine system, you are truly able
operator is ranked against a system target. - Other in-line process to monitor individual operators and
The best operators can be rewarded based • O verhead support for circular blades provide additional training where
on performance.” • Large screen performance monitors needed.
• Individual operator displays The StreamLine lets you look at each
StreamLine provides processors with a • Q uality Control Station operator individually and see which are
yield management system that utilizes our • E rgonomic Operator platforms consistently performing below target.
Innova software to give real-time feedback (adjustable) This, in turn, allows management to
to the operator and management on Yield, • A bility to handle multiple finished constantly move the average “StreamLine provides
Quality and Throughput. It is 24/7 oversight products performance to maximum performance.
and control over your operations. real-time feedback
Individual operator feedback
Flexible design maximizes return “The inline quality monitoring station has Monitored. Measured. Controlled.
on Yield, Quality
StreamLine can be used for fillet the ability to pull random or planned The new Stork poultry StreamLine puts and Throughput.”
trimming, thigh trimming/deboning, samples. In other words, the system has the reins of your operation firmly in
whole leg trimming/deboning and super the intelligence to target those operators your hands and the improved results
trimming. who are under-performing,” Graff directly on your bottom line.
Follow Headache-free tray logistics
us on: with Stork TrayTrack TrayTrack: the Marel Stork solution against
symptoms like disordered product flow, ad hoc
manual buffering, hidden costs and empty
packaging machines.
WARNING: This high-performance
labor-saving in-plant tray
handling system causes
headache-free tray logistics.
youtube.com/
marelstork Want to find out more?
marel.com/traytrack
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