BAADER Publication 1/2019

pdfpublish

100 Years

Innovating

Food Value

Chains

Our New Brand Promise

Ambitious in Digitalisation

Adding Another CAS Solution

New Breast Cap Deboner

Publication

2019 01


Content

Editorial

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Editorial

BAADER 100 Years Innovating Food Value Chains

New CEO Brings More Food Industry Knowledge to BAADER Poultry

BAADER’s Approach to Traceability

A Glimpse behind the Scenes

Remember the Past, Celebrate the Present and Plan the Future

The Value of Embracing Knowledge-Sharing

Improved Animal Welfare and Product Quality

Japanese Customer Invests in Further Automation

Big Business in Chicken Wings

Combining Automation and Manual Work to Optimise Quality

Animal Welfare, Flexibility and Product Quality in One Solution

Optimise the Return on Your BAADER Investment

Chef's Corner

Meet Us here in 2019

Dear Customer and Business Partner,

In 2019, BAADER is celebrating our 100-year anniversary.

A lot has changed over this century, but we have

kept many essential elements. We believe that the

best way to keep and grow close customer relationships

is to reach out and connect with them.

Our success continues to confirm our promise of reliability

and quality in all phases. This tradition will

remain true in 2019 and beyond. Over the past 100

years, we have achieved and delivered breakthrough

solutions through innovative technology and exceptional

skills.

This year, we are renewing ourselves once more

through extensive rebranding measures to reflect the

company’s evolution as a modern digital full solution

provider.

As part of the rebranding strategy, we decided to rename

BAADER’s poultry divisions, LINCO and BAAD-

ER LINCO. Starting in 2019, BAADER and all members

of the BAADER Group will use the BAADER name and

a joint corporate identity. Additionally, we welcomed

a new member to the BAADER management team:

Dr Norbert Engberg who will take over as CEO of the

Poultry division.

In this first 2019-newsletter edition, you can read

more about our new brand identity, our approach to

food traceability, digitalisation as well as the importance

of Aftersales and Service. You will also gain

some insides to our production facility in Doesburg,

NL and about our strong ties with selected customers

and research institutions. Several case stories

bring our product portfolio alive – from full wing segmenting

solutions and our semi-automatic breast filleting

to the BAADER compact plant.

Once again, thank you for your support over the past

100 years. Please join us as we celebrate this important

milestone. We look forward to a continued successful

partnership with you for years to come.

Enjoy the read,

Honorary Consul

Petra Baader

Executive Chairwoman

3.


BAADER 100 Years -

Innovating Food Value Chains

New CEO Brings More

Food Industry Knowledge

to BAADER Poultry

Re-Inventing Ourselves

With the beginning of our 100-year anniversary year,

BAADER is in the process of a major rebranding –

an ongoing process that we want the market and our

customers to participate in.

An important part of the rebranding is the decision

to use one oint name for all BAADER. Whether fish,

poultry, meat, fruits or vegetables - we believe that under

one name, we are stronger and better equipped to

leverage all our skillsets and capabilities across our

global company thereby serving our diverse customer

base better.

We redesigned the BAADER logo to portray our heritage

and evolution in combination with our new mission

– We Innovate Food Value Chains.

This new brand promises to reflect the past, current,

and future direction of the entire BAADER Group. Furthermore,

it will guide our creative spirit and passion

to find the best solutions and expand our partnership

with our customers into the digital age.

We Innovate Food Value Chains

What do we mean by that? Our knowledge and experience

in food processing technology is and remains

our core DNA, but it is simply not enough anymore.

We aim to look beyond our own value creation and

expand our digital scope to all kinds of stakeholders

working along food value chains.

By stating “We Innovate Food Value Chains” we emphasise

the four cornerstones of our mission:

/ The We in BAADER – We are one BAADER and

TOGETHER, we can drive

/ Innovation, covering the entire and several

/ Value Chains in and beyond food processing with

the goal of providing safe, quality and traceable

/ Food to global consumers.

During 2019, we will be changing our website, our

social media, our messaging and our focus to reflect

the way we help our customers succeed better.

What we are saying should not sound unfamiliar to

those who have worked with us. Our mission is only

a refined version of what we have always known well

about ourselves.

Dr Norbert Engberg brings food business

experience and strategic expertise that

will help us achieve our ambition to provide

poultry solutions that meet market needs

now and in the future.

/// I am excited to join this

successful and innovative

family company in a

challenging market ///

4.

/// Our new brand promise

reflects the past, current

and future direction of the

company. It reflects best what

drives us in our thinking and

acting ///

Petra Baader, Executive Chairwoman

We are happy to announce that Dr Norbert Engberg

joined BAADER as of 1 January 2019 taking on the

role of CEO in BAADER Poultry.

Engberg graduated in business economics with a

PhD and a German Diploma in Business Administration

at the University of Hamburg. He also brings

along more than 17 years of food industry experience.

The appointment is another important step to

strengthen our BAADER management team, particularly

in the poultry business. This provides a great

opportunity for a transition period where Engberg

and current interim CEO, Torsten Krausen, will work

together as a team to lead the BAADER Poultry business.

In the first internal meetings, I found passionate

teams running BAADER. I like to share facts and ideas

in teams to find the best solutions for our employees

and customers. We will work dedicatedly to bring

them to life. I also look forward to being part of this

year’s 100th anniversary celebrations and seeing the

company continue to grow and innovate in the years

ahead".

Dr Norbert Engberg,

CEO, Poultry

5.


BAADER’s Approach

to Traceability

Driving Entire Food Chains

Comes with Responsibility:

and It All Begins with Traceability.

Today some 7.5 billion people live on our planet

and the N estimates that this figure could rise to

9.7 billion by 2050. The requirements to meet food

demand now and in the future is what drives us to

continuously improve the food processing systems

we develop and install. It is important to act with

foresight and pay attention to sustainable value

creation.

Knowing where food comes from is vital to safeguarding

food product safety throughout the entire

production and distribution chain. The BAADER

digitalisation team is working on new ways to provide

traceability solutions that give our customers

the exact and real-time information they need as

to the local or international origin of the processed

food.

sing the latest in intelligent software, the aim is to

provide operators with a seamless stream of realtime

data, where adustments can be made uickly,

and potential weaknesses identified. This is not

only beneficial to the food value chain as a whole,

but also provides needed transparency for the food

processors and their customers.

BAADER Digitalisation at a Glance

/ Together with our customers and partners, we aim

to deliver the right information to the right people

at the right time

/ We trust that we can gain valuable information out

of data

/ By increasing our horion and data capturing from

various sources along the entire food value chain,

we can provide unprecedented info and verify

hypotheses and assumptions

/ We will deliver new ways of improving processes

and performance based on the exchange of

information

/ We believe that we can only be successful within a

strong network

/ We base all we do on the highest data standards

and a flexible combination of standard technology

/ Together with our customers, we will generate

new business models for our mutual benefit

What Driving Food Chain

Innovations Means in Digital Terms

Connectivity, cloud computing, artificial intelligence

A.I. and the general internet of things IoT have forever

changed the way the world does business. For

us, it represents a fascinating and rewarding new era

of greater efficiency, insight and customer profitability

all along the food value chain. Together with our

international team of engineers in both poultry and

fish, our digitalisation team is elaborating new, even

more effective avenues of production, operation and

smart design. By increasing our horion and data

capturing from various sources along the entire food

value chain, we can provide unprecedented info and

verify hypotheses and assumptions.

We recognise the huge potential of making a fully

transparent process and capturing real-time big data

to develop new processing systems and increase

overall value chain performance. By understanding

all influencers and underlying reasons that make up

for a specific process, we can optimise the process

in various ways:

/ By doing things differently

/ By introducing automation

/ By using new technologies

Technology Used

Our digital capabilities allow for capturing available

data from all participants involved in the food value

chain and storing them in highly secured and distributed

data centres provided by modern cloud providers.

Data security is a significant part of our digital

DNA and influences each technical decision even before

taking care of any single customer data.

Independent data streams along the food value chain

are further ingested into a centralised data lake providing

information according to customer needs at

the right time. Real-time stream processing helps

continuously analyse the data and ensures fully automated

and semi-automated process optimisation. A

huge amount of unstructured data can be evaluated,

combined with web-scale technologies thereby providing

sub-seconds decisions. The result preventing

any loss of valuable protein resources.

If you are interested in learning more about BAAD-

ER’s digitalisation approach, please contact your

Sales Representative.

From Farm to Fork – Creating Full

Traceability along the Poultry Value Chain

Ensuring traceability from farm to fork reuires

tracking the bird from its grandparents, through

its farm conditions and digitally record its status

during transportation or in different environmental

conditions. Once farm, feed, and storage data is entered

it would follow the bird's movements through

the supply chain like a passport.

Every time the bird crosses another checkpoint,

from farm, processors and the store, its status

would be signed and logged. A consumer could

then use a mobile app to scan the QR code on the

food product and in an instant, retrieve the itinerary

of the meat from farm to fork.

ltimately, the consumer could report back to the

entire value chain whether the chicken fillet she ate

tasted good or not.

/// Successful digital

transformation is really all about

people, and it starts and ends

with the customer in mind.

What are your needs? How can

customers easily and conveniently

use services, order or consume

products? Which digital offers

enhance the customer experience,

which ones lead nowhere? ///

Dr Stefan Frehse, Team Digitaliation BAADER

ow can traceability create a net positive value for

all stakeholders ow does it affect the consumers,

the regulators and all the companies that collectively

make up the food supply chain

1 Traceability can increase the ability to execute

faster.

2 Traceability can increase chain efficiency and

productivity resulting from improved product

labelling and tracking practices with the potential

to provide real-time visibility into product

movement through the supply chain.

Traceability helps analyse the supplier base, the

local food distribution system and implement

supplier development programmes or sustainability

management systems.

The outcomes of traceability are not

limited to only the business implementing

it - everyone from the suppliers to the

end consumers can use the information

carried by the tags.

Our platform allows for automated data

capturing with immediate access for

all participants as soon as they are on

it. aving access to real-time information

will allow them to better anticipate

changes in the upstream or downstream

part of the value chain

Sabrina Eer, Team Digitaliation BAADER

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A Glimpse behind the Scenes

Remember the Past, Celebrate

the Present and Plan the Future

The BAADER poultry business is composed

of several manufacturing facilities,

development centres and regional offices.

Let's take you on a trip to our Dutch

premises.

Grupo Oblanca has a long record of

accomplishments and their success

is enduring because of a set of stable

principles that guides the company

in their daily business and strategical

decision-making

Facts about Grupo Oblanca

/ Headquarters located in Leon, Spain

/ Family owned

/ Founded in 1958

/ + 500 employees

/ + 1200 products

/ 8 commercial delegations in Spain

/ 14,000,000 chickens per year

Expanding to Meet the Needs of the Future

In Doesburg, Holland, we have centred our expertise

in development and manufacturing of evisceration,

chilling and cut-up equipment.

To keep up with the increased workload in Doesburg

and to ensure future growth, we have just inaugurated

a new building that will house a larger Sales Engineering

and R&D. This will ensure that we have the

resources that we need to accomplish our innovation

strategy.

Finishing our Thigh Filleting System

The test of the new Thigh Filleting System 632 was

exceedingly successful and it is now prepared for a

controlled sales release, first in North America and

then globally.

Our Dutch team has been responsible for developing

and hardening the system both in-house and on

customer sites. These developments have proven

that the system lives up to our speed and yield performance

requirements. With the release of this system,

BAADER will help customers reduce expensive

product handling and trimming, and optimise their

thigh meat quality.

Our Dutch software development engineers are responsible

for creating a good user experience when

operating the Thigh Filleting System. They have developed

configurable production recipes that can be

selected on the HMI touchscreen to make it easy to

handle a wide weight variety in the flock intake. These

production recipes consist of set points related to

bird characteristics and other key settings necessary

to ensure the quality and yield performances.

New Wing Machines Are Ready to Fly

Our new anatomical Wing Tip Cutter 4142 and Mid

Wing Cutter 1 are also reaching the final phase

of development. For our Dutch engineering team

involved in the development of these wing-cutting

units, it was a goal that the new machines should perform

A-grade anatomical cuts and meet the growing

market demand for flexibility in the production of varying

bird sizes. They therefore came up with a unique,

now patented, method of cutting one wing at a time

to ensure a high degree of adaption in the individual

wing positioning. Furthermore, this method allows

for cutting one-winged birds and birds with broken

wings in the most optimal way.

The Thigh Filleting System is being developed and produced

in Doesburg, Holland

The Key to 50 Years of Successful Business

Grupo Oblanca celebrated their 50-year anniversary

with a big event in Leon, the same location as the

company’s headuarters. Almost 100 customers,

employees, authorities and other collaborators participated

in the event whose purpose was to remember

the past, celebrate the present and plan the future.

Of course, we could not be missing out on such

an important day.

When dealing with Grupo Oblanca, you clearly see the

importance that this company gives to its personnel.

It is a motivated and committed team that gives the

best of themselves every day, working in a professional

and honest way.

Javier Álvarez Oblanca, president at Grupo Oblanca,

constantly analyses the rapid changes that are taking

place in the market, affirming that his company

is ready to offer consumers what they demand now

and in the future. In this way, Grupo Oblanca is able

to launch an average of 100 new products a year in

order to adapt to the requirements of new buyers.

Old Acquaintances

Our relationship with Grupo Oblanca goes back almost

20 years. About our long-term co-operation, Bo

Schwartz (Regional Sales Director) says:

"I was always fascinated by the Oblanca family’s visionary

thinking and how they tirelessly try to innovate.

We delivered and installed the current plant in

Leon, and we are currently preparing the installation

of new machinery for the group’s newly acquired

facility in Ponferrada. Both from a professional perspective

and on a personal level, I greatly appreciate

the co-operation with Grupo Oblanca".

/// We always focus heavily on

analysing the future customer

demands. We know that during

the next years, the consumption

of our products will change in

terms of form, timing, quantity

and ease of consumption and

preparation.

We have already launched

several projects whose objective

is to anticipate and give us

answers to these new market

requirements///

Javier Álvarez Oblanca, President at Grupo Oblanca

8.

9.


The Value of

Embracing Knowledge-Sharing

Improved Animal Welfare

and Product Quality

We have added another CAS solution

to our proven nioad reception system.

Our customers can now choose

the solution that best suits their re-

uirements

Pedro Sucarrats Regional Sales

Manager, Spain closing the sales

contract with Javier Alameda Granero

Director General, INASR

Partnering with the academic side of

the industry offers insight and independent

knowledge, benefiting our

product developments

/// With great dedication to

animal welfare standards, we

partnered our high-quality,

industry-focused engineering

team with the experts in

poultry science at Auburn. The

co-operation will benefit our

customers and the industry as a

whole ///

Oliver ahn, CEO at BAADER INCO, Inc.

Oliver ahn CEO at BAADER INCO, Inc. shaking hands

with Paul Patterson Dean and Director, College of Agriculture

at Auburn niversity during the official donation

ceremony in Auburn, Alabama

Partnering with Universities

Our customers will be the first to benefit from the cooperation

between Auburn niversity’s Poultry Science

Department and BAADER on the development

of our new Controlled Atmosphere Stunning system.

The partnership was established in 201, when Auburn’s

poultry scientists and welfare experts started

the collaboration with BAADER’s engineers to develop

a new Above Ground CAS system.

Donation of CAS System

To provide Auburn's scientists an advantage in their

research on how carbon dioxide CAS systems impact

on animal welfare, we decided to donate our

first Above Ground CAS system to Auburn niversity.

With this donation, we will strengthen our partnership

between Auburn niversity and the Charles C. Miller

Jr. Poultry Research and Education Center.

The system will be installed in the Charles C. Miller Jr.

Poultry Research and Education Center’s new poultry

processing plant once construction is completed in

2019. ntil then, the euipment is located at the existing

poultry research farm.

Gentle and Humane Stunning

In our Above Ground CAS system, drawers are conveyed

on a robust, composite transport chain. A series

of chambers create a controlled stunning process.

The induction phase uses a pre-mixture of O and

CO to ensure gentle and humane stunning. Birds

are first exposed to relatively low CO concentrations

0 by volume in air including supplemental O.

Once the birds are unconscious, they are exposed to

higher CO concentrations 0–0 by volume in

air.

Stage length and gas concentration levels can be ad-

usted to optimise the stunning performance based

on product variables. The footprint of the stunning

system is determined by slaughter line speed and the

number of birds per drawer.

The Above Ground CAS in Production

Besides having tested the new Above Ground CAS at

Auburn niversity’s Poultry Science Department, the

system will now be installed at INASR in Crdoba

Spain. The Spanish customer already has a nioad

reception system installed and wants to implement a

CAS solution to meet their customers’ animal welfare

reuirements.

The conditions around the existing nioad reception

system are ideal for installing the Above Ground

CAS. Just a few conveyor adaptions are needed, and

the installation will not affect daily production.

We are happy to be able to offer two types of CAS

systems. Both systems deliver the highest animal

welfare stunning, but in different ways to adapt to

each customer's conditions and reuirements.

The simple hood-lifting design on the Above Ground

CAS system allows for quick access to the interior

of the machine during cleaning and servicing

10.

11.


Japanese Customer

Invests in Further Automation

Big Business in Chicken Wings

12.

When the equipment manages to show the

same results as skilled manual operators

in an automated way, the last argument

against further automation disappears.

Renewing the Existing Cut-Up

In Matsuyama, history and tradition meet digitalisation

and modern life style. In the city of Matsuyama

on the Shikoku Island, Bejoy Co. Ltd has established

their poultry processing plant, slaughtering about

3000 birds per hour.

When the need to renew the existing ACP6000 cut-up

line occurred, Bejoy examined both local and global

equipment suppliers to get the best insight into cutting

performances, yields and necessary manual rework.

Especially the latter has great impact on profits,

as labour is expensive in Japan.

Cutting the Wings on the Cut-Up System

We therefore decided to show Bejoy our latest anatomical

Mid Wing Cutter and Leg Processor in production.

The new Mid Wing Cutter has been thoroughly

tested at our show plant at Iqbal Poultry (UK) so we

were confident that Beoy could benefit from cutting

the mid wings directly on the cut-up line instead of

manually segmenting wings using four workers.

After seeing the great cut-up performance on both

anatomical legs and mid wings, Bejoy decided to invest

in a ProFlex Classic cut-up system from BAAD-

ER. The system includes wing stretching, mid-wing

cutting, pre-cutting, tail cutting, front half cutting and

leg processing (anatomical whole legs).

The technological advances that we experience within

poultry processing, and the increasing demands

Hans Gerritsen, Mr Tokuhiro, Rudi Polman and

Hidero Yamasaki

for processing speed and consistent product quality,

make automatic cut-up a good alternative to manual

work – even on markets where manual work has traditionally

been preferred.

Facts About Bejoy Co., Ltd

/ Headquarters located in Matsuyama, Japan

/ Founded in 1961

/ Meat packing plants and slaughterhouses

/ + 400 employees

/ Meat products, fresh fish, farm management

/ 1 poultry plant + several facilities for other products

/ 3,750,000 chickens per year

/// We are very satisfied with the

performance of the installed Leg

Processor, and particularly with

the new Mid Wing Cutter. The

yield for the Mid Wing Cutter is

excellent with a high percentage

of A-grade products. In addition,

we have saved labour costs.

Now we only need one worker

for inspection ///

Mr Tokuhiro, General Manager of BeJoy

As birds have grown bigger, so have their wings - and thus

the opportunity to increase profits in poultry processing.

BAADER offers a full wing-segmenting programme to

ensure the best use of the wing meat.

Make the Most of Your Wings

Chicken wings are truly popular in many parts of the

world, and wings often happen to be the priciest part

of the chicken. This fact makes wing processing a

high-focus area in today’s poultry processing. Precision

to achieve high-yield and quality wing products,

and flexibility to process different wing products are

all challenges that poultry processors face in daily

production.

The increased quantity of consumed wing meat as

well as an increase in bird sizes over the last decades

reuire more efficient and automated processing

technologies. Large wings with more meat volume

open up for wing segmenting and the segmentation

process is well paid.

Bypassing specific wing cutting units

ensures flexibility to process different

wing products

Anatomical wing tip cutting

Wing streching to ensure correct wing

position in the subsequent wing cutting

machines

Anatomical mid-wing cutting

Full Wing Segmenting

On our ProFlex cut-up line we offer a full wing segmenttion

programme: whole wing, drummette, middle

wing (mid joint), middle wing with tip and wing tip.

Our bypassing units on the cut-up ensure flexibility to

process different wing products.

When processing wings on an overhead in-line cutup

system, correct positioning of the wings in the

cut-up machines is crucial. Our Wing Tip Cutter 4142

and Mid Wing Cutter 4146 position and cut each wing

separately to optimise the cutting performance and

obtain an A-grade anatomical cut. By first cutting one

wing and then the other, the machines are flexible to

process varying bird sies. For further flexibility, both

machine height and segment width can be adjusted

according to bird size.

Sequentially wing cutting to position

each wing correctly regardless of bird

size

Anatomical whole wing cutting

13.


Combining Automation and

Manual Work to Optimise Quality

On our new Breast Cap Deboner 660 each

breast cap is measured to efficiently adapt

the cutting path and ensure high yield and

minimum rework.

First Class Fillets and Tenderloins

The global demand for white meat still rises steadily.

We therefore add another product to our already

existing breast deboning equipment - the new Breast

Cap Deboner 660.

Two operators load the breast caps onto the specially

designed saddles on the Breast Cap Deboner 660

after which the saddles carry the breast caps through

a mechanical deskinning, cutting and scraping process.

Finally, operators harvest fillets and tenderloins

manually on the saddles to ensure the highest fillet

and tenderloin quality.

The breast cap positioning throughout the automatic

processing steps is optimised by turning the saddle

according to the tools. At the manual harvesting station,

the saddle is turned into an upright position to

facilitate the work.

Intelligent Breast Cap Measuring

The machine features a measurement station that

measures the size of each breast cap. This measure

is used to adjust the deboning process automatically

to achieve the highest yield. Accurate cutting furthermore

minimises trimming labour after deboning.

Optimised Throughput

The machine can process matured and fresh breast

caps from 350g (12.3 oz.) to 950g (33.5 oz.). Variations

+/- 200g (7oz.) within one mechanical setting.

Throughput up to 3000 breast caps per hour with a total

of six operators, producing single fillets tender on

off, butterfly fillets tender onoff and tenderloins.

1

3

5

4

7

6

10

Our breast cap deboning and fillet trimming

systems are designed to optimise

the product flow as well as the working

conditions for the operators. This layout

example is designed to process 50

breast caps per minute (3000 per hour).

8

9

1 Workers load the breast caps on the saddles.

2 Skin is removed from the breast caps and

discharged (optional).

Automatic wishbone harvesting.

Several pre-cuts are performed depending on

the product being processed.

Manual harvesting of fillets and tenders.

Deboned carcass frames are conveyed away

into a BAADER Separator.

Manually harvested fillets/tenders are conveyed

to a trimming table. Products that do not

require additional trimming are conveyed away.

Workers ensure that the fillets/tenders are

oriented correctly for scanning on the X-Ray

Scanner 886.

9 The X-Ray Scanner 886 scans the fillets for

bones. When bones are detected, the machine

rejects those fillets for additional trimming.

10 An elevating conveyor transports the rejected

fillets, returning them to trimmers for final

trimming. Once final trimming is completed,

the fillets are placed back into the product

stream and checked for bones again by the

X-Ray Scanner 886.

2

14.

15.


Animal Welfare, Flexibility and

Product Quality in One Solution

2

Hopballe Mølle is taking advantage of the

adjustment flexibility on the Compact

Plant. The result is an improved product

quality and yield.

/// We wish to offer our customers

the highest ordering flexibility,

and that makes demands on our

processing flexibility. By controlling

our own slaughter, cut-up and

packing process, and all the logistics

around it, we have achieved a higher

product quality and more flexibility in

our daily production ///

Brent Christensen, Owner of Hopballe Mølle

4

3

5

6

1

1 Compact Plant 396

2 Slaughtering zone

Evisceration zone

Chilling zone

Whole bird weighing

Manual cut-up zone

Facts About Hopballe Mølle

/ Located in Jelling, Denmark

/ Family owned for six generations

/ 10 employees working in the slaughter plant

/ Producing 800 chickens per hour

/ 2 - 3 kg birds (eviscerated weight)

/ Approx. 20% whole bird packing and 80% cut-up

A Niche Production

Brent Christensen is the sixth generation owner of the

family farm Hopballe Mølle. It was originally built as a

water mill, but for generations animal husbandry has

also been part of the family tradition. In 1982, Brent

Christensen took over the farm after his father, and

he chose to specialise in chicken breeding. Although

he started with conventional breeding, he has today

changed to a niche production that gives him and his

chickens an enviable reputation with the customers.

A Hopballe Chicken is famous for its meat quality.

The chicken production in Hopballe Mølle is based

on the family’s desire to live up to the highest animal

welfare requirements, and the chickens are given the

best conditions for a healthy life with quality food and

plenty of room to be active. The breed is Label Rouge

and the chickens are sent to slaughter when they are

60 - 85 days old.

Taking Control of Processing

Hopballe Mølle has previously left the slaughtering of

their chickens to neighbouring slaughterhouses, but

due to the special characteristics of their birds, they

would typically not fit into a normal production setup.

By investing in a Compact Plant 396 the company

is now able to adjust processing to the birds' characteristics,

thereby improving both quality and yield.

Due to the size of the birds, the Compact Plant 396

is equipped with a 12" overhead line to ensure space

around each chicken during processing. It allows for

processing 800 big birds per hour. Brent Christensen

explains: "before we had to high scald our chickens to

ensure a good picking result. On the Compact Plant

396 we low scald and still we get a good picking result,

and additionally a nicer colour of the skin. Furthermore,

at 800 birds per hour, our people have time

to perform a proper manual evisceration and obtain

the quality product that we promise our customers.

We are happy to see an increase in our yield performance

and fewer downgrades. The fact that we now

slaughter the birds less than 100 metres from the

barn increases the welfare of our chickens, and the

financial savings from the changed logistics are also

significant.

Taking Up a Challenge

As Hopballe Mølle was in a hurry to start up their own

slaughtering, cut-up and packing, we had less than

a month to deliver and install the small, compact

slaughterhouse. Luckily we had a Compact Plant

396 that we had run demos on, and we could quickly

prepare it for Hopballe Mølle. The production was

started up 3 January. The complete delivery consists

of a Compact Plant 396, an air cooling tunnel and an

EasyGrader to weigh whole chickens.

"It has been an exciting project, both because of the

time challenge, but also because of the bird size and

characteristics. Due to the bird sizes, we removed

every second shackle on the Compact Plant 396 to

change from a 6" to a 12” overhead line to ensure

proper picking, in particular between the legs and

around the vent. This simple task was done in less

than 20 minutes without the use of any tools. Despite

the very big birds and large variations in bird size, we

quickly achieved a quality product that lives up to the

Hopballe Mølle name.

/// This project confirms

the importance of having

implemented a high degree

of flexibility into the Compact

Plant 396 ///

Karsten Nielsen

Mechanical Engineer, R&D

This proect confirms the importance of having implemented

a high degree of flexibility into the Compact

Plant 9. Bleeding time, scalding timetemperature

and shackle speed can be adusted to fit processing

requirements, and Hopballe Mølle has indeed understood

making use of these adjustment possibilities".

Karsten Nielsen

Mechanical Engineer, R&D

16.

17.


Optimise the Return on

Your BAADER Investment

Chef's Corner

Large sums of money are invested in modern

processing equipment and daily live bird intake.

We offer on-site audits that can help you get the

best of your investment.

Drumettes

in Orly Dough

Take a Proactive Approach

In order to rise ROI you need to be proactive in your

machine maintenance. Regular maintenance is less

costly than major equipment breakdown or poor

machine performances. Spare parts availability will

shorten any breakdown. Intelligent machine adjustments

will reduce product damage and improve endproduct

quality. Your ability to run a sustainable poultry

business relies on efficiently running machinery

and optimised processing.

We take a holistic approach to production optimisation.

We consider the complete value chain as our

main target, not a single machine or line. Optimisation

includes birds, machines, processes, people,

products and IT. Therefore, we offer our customers

on-site equipment evaluations based on extensive

production audits. Our goal is to prepare the customer

to understand how regular and correct maintenance

affects machine performance and product

quality, and how the variety of adjustment possibilities

interact and effect the overall production performance.

Senior Technical Consultant Manager, Hans Gelens, offering

maintenance tips in China

Ingredients

5 drumettes

For the Orly Dough

00g wheat flour

1 egg

4 egg whites

4 dl beer

2 dl lukewarm water

1 dl oil

Salt and pepper

How To

Serves 5 Persons

Whip all ingredients except the egg whites well to the dough and

allow it to rest for an hour before the egg whites are whisked

rigidly and carefully mixed with the dough.

Heat oil in a small pot to approximately 180° C / 356° F. Dip the

drumettes in the Orly dough and deep fry in the hot oil until it is

completely golden and crispy (approximately 5 minutes). Remove

the drumettes from the oil and leave to drip dry. Serve on

fresh, green salad.

Enjoy!

Luciano Simmini

Chef at BAADER’s poultry division in Denmark

Workshop at San Miguel Pure Foods

San Miguel Pure Foods is one of the leading food

companies in the Philippines. As business has developed,

processing has become more complicated.

More factors influence the final product uality

and more production options become available. We

therefore offered San Miguel a workshop in Manila

where more than 30 service and maintenance technicians,

owners of San Miguel Toll Partners (Sub-Contractors)

as well as operational managers from the

San Miguel Group attended.

It was a hands-on workshop where the customer

worked on his own production line while being

coached by our Senior Technical Consultant Manager,

Hans Gelens.

Do you want an audit by one of our

consultants? Please call your local

representative

18.

19.


Meet Us Here in 2019

12/02 /

IPPE, Atlanta, US, Poultry

07/03 /

Foteg, Istanbul, Turkey, Separator

12/03 /

CFIA, Rennes, France, Poultry

13/03 /

VIV Asia, Bangkok, Thailand, Poultry

17/03 /

Seafood Expo North America, Boston, US, Fish

04/05 /

IFFA, Frankfurt, Germany, Separator

07/05 /

Seafood Expo Global, Brussels, Belgium, Fish

21/05 /

Atlantic Fish Fair, Faroe Islands, Fish

03/06 /

Indo Livestock, Surabaya, Indonesia, Poultry

13/06 /

VIV Turkey, Istanbul, Turkey, Poultry

10/07 /

Seafood Expo Russia, St. Petersburg, Russia, Fish

25/07 /

AAMP Convention, Kansas City, US, Poultry

20/08 /

Aqua-Nor, Trondheim, Norway, Fish

18/09 /

Ildex Indonesia, Jakarta, Indonesia, Poultry

25/09 /

Icelandic Fishing Expo, Reykjavik, Iceland, Fish

30/09 /

Polagratech, Poznan, Poland, Poultry/Separator

02/10 /

Poultry Africa, Kigali, Rwanda, Poultry

03/10 /

AVEC, Budapest, Hungary, Poultry

07/10 /

Agroprodmash, Moscow, Russia, Poultry/Separator

08/10 /

OVUM Congresso, Lima, Peru, Poultry

08/10 /

Process Expo, Chicago, US, Separator

21/10 /

Saudi Agriculture, Riyadh, Saudi Arabia, Poultry

30/10 /

China Fisheries, Qingdao, China, Fish

05/11 /

Gulfood Manufacturing, Dubai, UAE, Poultry/Separator

This brochure is current as from the publication date and supersedes all previous versions. The English version is perceived as the master

document and all other versions are subject to incorrect translation. The indicated limits of the working ranges and performances may vary

as a function of the proportion, quality and nutritional conditions of the birds. In order to achieve an optimal result, it is recommended to

adjust the machine within the working ranges of the bird sizes mainly to be processed. Illustrations and dimensions are approximate and

not binding. Subect to design changes in the interest of technical progress. Actual scope of supply is specified in our uotations and order

confirmations and may differ from descriptions and photos of this brochure.

Attention! For the illustration of the technical details the safety devices and protection mechanisms are partly not shown in operative condition.

When operating the machine, all corresponding devices and instructions referring to the safety of the machine are to be utilised and/

or observed.

www.baader.com