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Automatic Slaughterhouse Process
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Livestock Arrivel Department
This section is the initial part of the chicken and poultry processing process.
When the chickens are ready for slaughter, they are loaded into vehicles and brought to the slaughterhouse.
Generally, this process is done by placing chickens in plastic crates and loading them into vehicles.
When the chickens to be slaughtered are brought to the slaughterhouse, the operations are carried out by considering the poultry health as a priority. Taking this into account Machinery and equipment needs to be used are provided.
Machinery and equipment are selected according to the capacity of the facility.
Cutting and Plucking
In this process, live chicken is slaughtered. However, the functionality of the machines here is very important. Another point to be considered in this section is that the chicken is exposed to the interventions of the machines in the most appropriate way ethically and psychologically.
This process line The main subject is to cut the chickens and clean them from their feathers and make the internal organs ready for cleaning. This process takes place using different machines and equipment. The more clean and neat the chicken that comes out of this section, the easier the process in the next section.
The modular structure of the line in this process provides an easy solution for a possible capacity increase in the future. Thus, there is a chance to make modifications on existing systems. Here, many safety precautions have been taken and an efficient, rapid and energy-friendly process has emerged.
Automatic Viscera Removal
It is this part of the poultry processing process where equipment and machinery are the most complex. The quality of the cleaned internal organs (liver, gizzard, etc.) is very important as well as cleaning the internal organs of the chickens coming from the slaughtering and plucking department.
Especially in high capacity usage, with the line rotating at high speed, it will be very difficult to do this with human power and will remain at a very low level in terms of efficiency. In terms of efficiency and series, every machine in this section and every station on every machine performs the same quality treatment for all chickens from start to finish.
The machines in this process have their own specific tasks. Each one works synchronously with the conveyor line. Having a mechanical structure ensures the long life of the machines. In addition , many adjustment options are offered according to the average chicken weight and size , ensuring that each machine works with full efficiency .
Water Cooling
Washing and cooling is a very important process for the quality of chickens. The cooling process takes place in two different ways. Which of these two options is suitable is selected according to the capacity and customer demand.
Projects where the first option (water cooling) alone is sufficient are mostly low-capacity facilities. As capacity increases, both systems must be used. The main purpose of this section is to ensure that the body temperature of the chickens, whose slaughter and internal organs are cleaned, reach lower values before being exposed to the air cooling process. This ensures that the chicken undergoes a better quality cooling process. This process is a positive factor for both chicken quality and product life. Thanks to the cooling done with water, the chickens are cleaned at the same time and sent to the cold air section.
Air Cooling
Cooling is very important in a food process and directly affects the product.
In poultry slaughterhouses, this process is extremely important and requires attention. The important point is how long the product stays in the cold room and how many degrees the room temperature is. Calculations are made taking into account all these and the health of chicken meat.
As a result of these calculations, the most suitable conveyor length emerges. Too much cooling of the chicken is harmful, too.
The quantity of the conveyor system varies according to the capacity.
Weight Classification Department
It is the most complex part in terms of process in a chicken slaughterhouse. Here chicken weight, quality and weight is done automatically by the computer on the separation line panel. The chicken that comes to the line using a special hanger is classified by determining its weight.
A loadcell on the line performs the weighing operation and transmits the information to the computer program. These operations are performed with millisecond precision thanks to the use of PLC. The chicken, which belongs to the pan determined according to the weighed weight, falls into the pan it belongs to, thanks to the pneumatic reducing stations on the line.
Our weight sorting line has the ability to make the most accurate weighing despite the conveyor lines rotating at high speeds.
Auto Shredding
In the chicken processing process, the products are structurally integrated from start to finish. An automatic shredding line is used to break this integrity. Piece and whole chickens are sold according to market needs. Here, the important thing in terms of investment is to offer the product that is suitable for the demand of the market. The automatic shredding line is a system with a unique platform structure and conveyor. There are special hangers on the conveyor and special routers on these hangers. The reason for this is to adjust the standing position of the machine and chicken according to the area to be slaughtered.
The automatic shredding line performs efficient, rapid and accurate shredding in high-capacity plants. Shredding takes place with machines connected to the line but working independently of each other. In the shredding line; It consists of end wing cutting, bottom wing cutting, beehive breast and special breast cutting, middle splitting, baguette cutting and reducing machines.
In addition, guides to adjust the direction of the hangers between each machine are mounted on the conveyor. Adding and removing machines can be done easily on the line, which has a modular structure. The cutting knives were covered with guards and safety measures were taken by placing emergency stops. There are mechanisms for making height adjustment and guide guide adjustments on each machine. In this way, it can be easily shredded in various weight groups. The location of the shredding line is specially selected and produced according to the project.
Packaging Department
The final stage in processing is packaging. Packaging The process is done in a serial and hygienic manner.
This process belt consists of a pneumatic bagging machine and a clipping machine. Pneumatic bagging machine and clip machine are mounted on the belt.
The bagging machine works with air. So the worker just takes the chicken and puts it in the bag. The worker, who takes the bags from the band, also performs the clipping process in a rapid manner and completes the packaging process in the highest number in the shortest time.
The packed chicken is transported to the cold storage and is ready for shipment.
Waste Division
Plant cleanliness is very important in food processing systems. In the poultry processing process, a lot of waste and garbage is released. Garbage is extremely valuable in terms of both recycling and energy.
Waste garbage separator and pump group are used for the evaluation of this garbage released in the facilities. Especially the poultry wastes formed in the facility are used as raw materials for feed, thanks to the rendering system. Another issue is environmental cleanliness.
Waste and garbage that will occur in the facility should be under control. It should not be forgotten that cleanliness is very important in the facility, which is a whole from the live entrance to the product shipment. Poultry Tech Group Thanks to the system it has developed to take all these under control, it ensures that the hygiene rate in the facility is at the highest level.
The project of the facility to be established is designed accordingly from the very beginning. Because the canals and wells where the garbage will be collected are made in the first step of the architectural project. Machine layouts are determined according to this channel plan. Thus, the facility is constantly free of waste during and at the end of the work.
System Control Panels
The control, management, safety and main power supply of all equipment in the poultry process is realized thanks to the system control panels. The boards are divided into sections within themselves. Each section has its own board.
In these panels, it is fed from the panel where the main energy is located. Many options such as motors in the machines, reducers on the line, emergency stops, speed of the conveyor line are controlled with a single button on the panels.
A lot of information such as which machine is working, which machine is malfunctioning, conveyor rotation speed, some values on digital indicators can be seen on the panel during operation and information is obtained.
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