PNewsletter o u lt ry F R O M
B A A D E R
L I N C O
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W W W . baader . com
70 years of innovative food processing solutions
2014 is a special year to us. This year we are able to commemorate the 70th anniversary of the founding of our company. When the Lindholst family first started the company in 1944 in humble premises in Denmark few would have predicted that it would end up being part of an international and world leading manufacturing group, The BAADER Group. Originally the Lindholst family made a commitment to make customer service their primary focus, and this decision has undoubtedly been one of the keys to our longevity and success. Another key to our success is our people. We have staff that has been with the company over 40 years and their specialist knowledge and vast experience has been essential to our growth. We would like to express our gratitude to loyal customers who have contributed to the creation of our motto “grow with us” and the employees who have dedicated their professional lives to the company’s continued growth.
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j an u ar y 2 0 1 4 Message from CEO
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Knowledge sharing in Turkey
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Proper bird handling pays off
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BAADER LINCO, Inc.
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Breast Deboner 656
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Skinner 625
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Increase food safety
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Poultry in Argentina
First class weighing
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B’Logic® Grading
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B’Logic® Label Composer
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Meet us here in 2014
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Poultry newsletter G row w i t h u s
Message from CEO “2013 was a successful year for the BAADER Group. We have experienced a profitable growth and we have been honoured with two prestigious Danish awards. 2013 was also a year of change for BAADER LINCO, and I am proud and humbled to become CEO for this organization that I have a profound respect for. I feel extremely motivated to serve customers, board members and employees throughout the world, and I look forward to seeing further innovation, market growth and employee commitment. 2014 will undoubtedly be a year full of new product releases, exciting engineering challenges and close customer collaboration.” - Andy Miller
“Our Grow with us slogan has never been more relevant
“The Most Excellent ERP Project Of The Year 2013” This award, presented by the Danish consulting company, Herbert Nathan & Co, goes to a company that has distinguished itself by implementing an ERP project with excellence. For BAADER LINCO the new ERP system has improved quality, validity and the speed at which we can gain insight into data.
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than now” - Andy Miller, CEO
The Gazelle award is presented by the Danish newspaper Børsen. The newspaper was founded in 1896 and focuses primarily on business and financial topics. In order to be selected as a Gazelle company the company needs to show a continuous growth in revenues or gross profit over the past four financial years, and it must have more than doubled revenue or gross profit in the period. The award is based on data from the Danish Commerce and Companies Agency.
Poultry newsletter keep i ng t h e f i nger on t h e market p u l s e
Knowledge sharing in Turkey In October 2013 we conducted a large-scale sales seminar inviting sales personnel from around the world to share experiences and provide input for future market driven development. The objective was bringing together BAADER LINCO people working in “the field” and map the extensive knowledge they have about their markets. During the seminar we were honoured with Mrs. Baader’s participation and clear interest in following market tendencies closely.
Throughout this newsletter we will share some of the market knowledge and processing experience that was highlighted during the seminar.
Special thanks to As Piliç The sales seminar was held at our customer and trusted partner As Piliç’s poultry plant and we would like to thank As Piliç for opening the doors to the plant in Sakarya, Turkey. Turkey is a fresh and air chilled market that places great demand on scalding and picking processes and the production in Sakarya was perfect for studying first processing details and sharing experiences across countries and continents.
Mr. Naci Kaplan & Mrs. Petra Baader
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Poultry newsletter Q u al i t y i s not an act , i t i s a h ab i t
Proper bird handling pays off Focus on product handling in reception and first processing can improve the meat quality significantly. Live bird handling and first processing are particularly important processes to obtain a good end-product quality as injuries added to the birds in these processes cannot be remedied.
sively forcing the bird by pulling legs downwards • If not implementing CAS, our Breast Comforter can help birds to relax and not flap the wings excessively from the time of shackling to electrical stunning
The logic of animal welfare To us it is pure logic that animal welfare and return on investment go hand-in-hand. Farmers take good care of their chickens through correct incubation, feeding, lightning, immunization and final catching. So why compromise on animal welfare in the poultry processing? Gentle live bird handling is essential for maximized yield and end-product quality, and this is eventually reflected on the bottom line. In BAADER LINCO we have spent years developing equipment that takes live bird welfare and gentle product handling into account. Live bird handling and shackling • Full crates are not manipulated during the catching operation. Once full, they remain in the crate and an empty crate is slid over the full crate thus reducing the injuries in the catching process. • Drawer design offers good foothold to birds and thereby less injuries during transportation • Large-size drawers enable a low-speed reception system to feed a high-speed killing line – low speed improves bird conditions • Good ventilation during transportation and storage reduces stress • No rough handling of live birds by dumping • CAS stunning reduces stress and injuries during shackling • Our foot pusher will ensure proper hanging without exces-
for optimum 4
ANIMAL W E L FA R E
Poultry newsletter
Optimized first processing BAADER LINCO delivers prime first processing equipment. We have experienced people with extensive regional knowledge that can design the optimum flow through stunning, bleeding, scalding and picking – the very foundation to avoid irreversible product damages. The equipment is efficient and adjustable to fit the product being processed, e.g. individually adjustable picking rows to ensure correct picking despite a great variety of bird sizes.
First processing performance can be constantly monitored by our vision quality classification system, the ClassifEYE®. In-line collection of detected injuries can be used to take immediate actions to improve first processing. The nature of the bruises indicates if caused by farm damages and violent live handling, ineffective stunning, wrong picker adjustment, over-scalding etc. Immediate corrective actions prevent further avoidable downgrades and subsequent profit loss.
Examples of ClassifEYE® camera detections:
Feather detection caused by improper scalding or picking
Wing injuries caused by rough live-bird-handling
One-leg-hanger caused by poor shackling
Breast bruises caused by rough live-bird-handling or during stunning
e x pert to e x pert Effective stunning Effective electrical stunning is essential for high meat quality and yield performance. The best indication of correct electrical stunning is the appearance of the stunned birds. Evaluate the birds coming out of the stunner and going in to the knife: • The neck should be arched with head held vertically • No rhythmic breathing • Rigidly extended legs • No wing flapping Tips to ensure continued effective stunning: • Size of shackles must be appropriate for the size of bird (legs) • Connection of the shackle line to the earth rail should be constant • Where possible, all shackles should be filled so all birds receive the same current in average
Avoid pre-stunning Birds may suffer painful pre-stun electric shocks (usually through the leading wing) at the entrance of the stunner. Pre-stun shocks affect meat quality and profit negatively: • Ensure that shackling and stunning area is properly darkened and kept quiet to prevent birds from flapping wings • Use a chicken comforter in full length from shackling to stunner entrance to relax birds • Ensure there are no sudden dips, turns or jolts in the line • Check the water level – birds should immerse to wing base. BAADER LINCO stunners have automatic water control • Induce immediate unconsciousness with an adequate stun 5
Poultry newsletter B A A D E R L I N C O , Inc .
North American trends The outlook for the global poultry industry is improving in most regions of the world, driven by better market balances, ongoing high competitive protein prices and lower grain costs. The North American poultry industry continues to post strong profitability, which is attributed to a combination of both supply and price discipline. In addition, supplies of competitive proteins are tight, providing a good basis for solid pricing in the poultry sector. Further processed food From a consumer´s perspective poultry meat is attractively priced when compared to beef, pork and fish. The consumer also has an ever expanding choice in poultry meat offerings: Fresh, frozen and precooked products such as chicken fillets, thigh meat, strips, wings etc. in all kinds of tastes. Automated processing A continuous improvement in the economy might lead to a rise in labour costs and thus a derived increase in automated processing equipment, e.g. deboning and skinning. BAADER LINCO offers very competitive and unique solutions to help our customers produce their products in the most efficient and flexible way. We help our customers deal with ever higher labor cost and availability concerns while also giving them maximum flexibility as to which final products their customers demand. For our customers that are heavily investing in deboning, BAADER LINCO has just recently introduced the new High Speed 656 Deboning Machine and the 625 Skinning Machine on the US market. To learn more about this equipment please turn to page 7 and 8 in this newsletter. Focus on animal welfare Increased health consciousness within the North American population also tends towards a higher consumption of fresh poultry products, and another tendency is an increased animal welfare consciousness that might soon be followed by legislation on the protection on farmed animals at slaughter. The market is demanding focus on animal welfare in farming and live bird handling.
BAADER LINCO is ready to meet the demand with our live bird handling system, a complete integrated system that ensures birds are loaded, transported and unloaded at the processing plant in the most cost effective and efficient manner without causing any stress or carcass injuries. This leads to maximized yields and more A-grade product out the door while adhering to the highest of animal welfare standards. The system can optionally be equipped with our proprietary controlled atmosphere stunning system which has been developed with and approved by major research institutes.
Announcement
The name of our US section is now officially changed from BAADER Johnson Food Equipment, Inc. to BAADER LINCO, Inc. The name reflects our common identity but US customer contacts, production facilities etc. remain unchanged. As a result of organizational changes, Mr. Oliver Hahn has been appointed COO, Mrs. Karen Brady CFO and Mr. Twan Winkelmolen VP Sales & Marketing.
Oliver Hahn, Karen Brady & Twan Winkelmolen
e x pert to e x pert Promote your product Poultry processors who make an effort to protect animal welfare or the environment will have a marketing opportunity to tell their story. A good medium for this could be the label information, for example a QR code referring to a website, a presentation video, etc. Our latest generation of label design software, the B’Logic® Label Composer allows for inserting QR codes. 6
Poultry newsletter E l i m i nate random i z i ng from front h alf debon i ng
Breast Deboner 656
Key benefits:
• Automatic tool adjustments for a customized deboning and optimized yield performance • Handles both wing-on and wing-off front halves • Produces single or butterfly fillets with tender-in or tender-out • Recovers the back meat separately or attached to the fillet • Recovers the yagen or the wishbone from the carcass • Real-time production monitoring and optimizing adjustments
Skinning
Individual measurements
Wishbone cutting
Back scraping
Precise cutting
Traditionally breast deboning has been one of the most labourconsuming operations and manual deboning requires proper training and workers´ compensation in order to ensure yield and quality. The main difficulty in automating the deboning process is the varied character of the process due to the natural variability of bird sizes and shapes.
sizes and avoids pulling the meat off the frame. The machine produces an extensive list of breast meat products and can furthermore be equipped to process whole or segmented wing products. Processing 85 front halves per minute the amount of operators needed is reduced from 31 to 10 compared to manual deboning*.
The BAADER LINCO Front Half Deboner 656 represents an intelligent deboning system that measures each front half in order to adapt the deboning process to the individual product size. The result is high throughput, maximized yield and product quality. Because of the automatic tool adjustment system the Deboning Machine handles a wide range of product
Production data from the Deboning Machine can be viewed in real-time on the shop floor. This constant monitoring enables our customers to overview production and correct it immediately if out of target – even during production.
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* compared to a cone line running 36 cones/minute
Poultry newsletter
Note: Only released in North America
h i g h q u al i t y s k i nn i ng
Skinner 625
Key benefits: • • • • • • • Skinning roll, knife and flapper roller
Drive belts
Drive sprockets for conveyor belt
This machine is distinguished by its fast and flexible setup that allows a gentle but effective skinning process without damage to either the meat or the skin. When skin is removed in this way, yield is maximized and so is profitability. Adjustments are held to a minimum to keep machine operation simple. The only adjustment is the gap between the knife and the skinning roller, and the location of the pressure roller. Depending on the product to be processed, different combinations of skinning rollers and pressure rollers are required. These few and simple adjustments allow the machine to skin multiple chicken products. During the skinning process the pressure roller will adjust to the different product heights automatically. However, the initial pressure roller height can be pre-adjusted to fit thicker or thinner products. 8
Consistent, high quality skinning performance Flexible set-ups allows for maximum yield or maximum trim configurations Simple to operate, disassemble and clean No daily adjustments required Robust design provides for low maintenance and cost of ownership Timing belt drive system Controlled pressure and water consumption
The Poultry Skinner 625 is suitable for removing skin and undesired fat from fresh chicken breasts fillets (singles and butterflies), whole legs, drumsticks and thighs. Cleaning the machine is an easy matter. The machine disassembles in an instant and all parts entering in direct contact with meat can be removed without using tools. This is indeed a machine that fully meets our aim to develop machines that are simple, durable and effective.
Poultry newsletter N ew B A A D E R L I N C O i n s pect i on s ol u t i on
Increase food safety
Note: To be released in 2014
How the 886 X-ray Machine learned to detect bones in chicken fillets Early in 2013 Rose Poultry A/S, Denmark, was contacted by BAADER LINCO’s Development Director Uffe Thrane and asked if Rose would be interested in having the new X-ray Machine model 886 on trial.
Key benefits:
• Consistent, high end-product quality • Prevention of customer claims • Fast and automatic calibration: 20 seconds once a day • Valuable feedback for upstream adjustment on deboning machinery • Reduction in manual product handling and thus labour costs • Hygienic design – no curtains in order to prevent cross-contamination High volume production and increased food safety demands generate a pronounced need for automatic bone detection in the poultry business. Visual inspection is labour intensive and often results in missed bones and thereby poor food safety. The new BAADER LINCO X-ray Detection System allows our customers to optimize both production speed and end-product quality. The x-ray technology enables an effective and consistent bone detection: >99% of the poultry bone particles as small as 2 mm in size (provided sufficient calcium content). The X-ray 886 performs an automatic calibration on each machine start. No stop or user interaction regarding any recalibration is necessary to maintain the machine performance during one shift of production (8-10h). When detecting bones in the meat, the product is automatically rejected and sent to an operator who manually removes the bone. For absolute food safety the product is re-scanned before allowed to continue to further processing.
As Rose was already researching the market for new x-ray machines it was soon agreed that BAADER LINCO was to install a machine off-line in order to test the ability of the new x-ray machine to detect bones in chicken fillets. It soon proved that bones intentionally placed in bone-free fillets were easily detected. Fillets coming directly from Rose Poultry’s automatic deboning line were then presented to the X-ray Detection System. After having the BAADER LINCO team systematically fine-tuning the software, the plant management of Rose Poultry A/S and BAADER LINCO agreed in late summer 2013 that the machine performance was so good that it could be installed in-line on one of our two deboning lines. This gave Björn, Stephan and their team a good opportunity to further fine-tune the machine in order to optimize performance. Today the machine practically complies with the objectives that we initially set together with BAADER LINCO, and caused by its satisfying performance, we are currently changing the set-up of the line where the 886 X-ray Machine is installed. We are now ready to continue with the installation of a new belt grading system after the x-ray machine in order to further test on the complete line. This will eventually change the way we handle deboning of our fillets. Contributing to developing new machinery together with BAADER LINCO has been both interesting and instructive and we are sure that the final solution and layout for our trimming and bone detection section will be finished before the end of the first half of 2014. We give great credit to the BAADER LINCO team. They have been working highly systematically and industriously and not least, the dialogue and follow-up have been very satisfying. Torben Brandt Sørensen Plant Manager, Rose Poultry A/S
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Poultry newsletter grow i ng toget h er w i t h s o y c h ú
Poultry in Argentina
1 Argentina is one of the South American countries that has experienced the greatest increase in production of poultry meat over the past 10 years. Both domestic consumption and exportations have experienced growth. Argentina might traditionally be known for its exports of red meat, but in fact, today poultry exports represent an equally large proportion of the total exports.
The BAADER LINCO loyal customer, Frigorífico de Aves Soychú, is a good example of the development of the Argentine poultry processing industry. The company was founded in Gualeguay (Argentina) in 1962 by the Santangelo family and the first plant originally processed 150 birds per hour. In the 1970s the company initiated a continuous expansion and modernization of production that continues today. Nowadays, the customer has two processing plants where weighing and sorting is controlled by LINCOflex. The product portfolio covers whole chickens and cut-up products. The export markets consist of 38 countries in South and Central America, Africa, Europe and Asia. In BAADER LINCO we have followed the customer closely in this development process as our cooperation goes back more than 30 years. When the customer started modernizing in the 1970s, we installed the first overhead weighing system (LINCO tronic 0) at Soychú which was replaced by a new system 18
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14 years ago we installed a belt weighing system for handling whole chickens and now requirements to the processor’s production system have increased further up to 14,000 bph. In Argentina whole birds are often packed in boxes with 20 kg fixed weight and as the presented BAADER LINCO grader solution offers both high throughput and precise batching, the customer has chosen to continue many years of cooperation by buying a new grader system able to handle 300 whole birds per minute. The complete dual lane solution consists of: • Feeding conveyors for bagged birds with moveable tables for sealing units • Flexfeeders with product sensors for controlling product identification and ensuring high speed in-feed to the grader system • Acceleration conveyors for correct spacing before weighing
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Flighted loading conveyor 10
years ago. This latest installed system is still used in today’s production.
In-feed to high speed Flexfeeder
Poultry newsletter
Key benefits:
• Multiple product handling • Easy operator loading – high speed grading • Layout flexibility obtained by flexible feeding conveyors • High operator comfort for more efficient packing • Stable and durable construction
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• • • • •
High accuracy weighing units Distribution conveyor with double batching bin Packaging supply conveyors Packing tables Product take-away conveyors
The grader system will handle small eviscerated birds in preprinted bags for export markets and at the same time big, bagged birds for the domestic market. The existing overhead system distributes the birds to the correct bagging operators, after which the bagged birds are loaded into pockets on the flighted conveyor. Based on the loading position a sensor records the product type. The Flexfeeder transfers the bagged products to the grader system with the optimal space between products in order to maximize throughput. The product identification captured by the sensors and the weight captured by the dynamic weighing unit enable the system to batch products into target weigh and count.
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Collecting bins on whole bird grader 11
Poultry newsletter G rad i ng po u ltr y part s
First class weighing
Key benefits:
• Highly accurate weighing • High machine reliability ensured by robust design and low maintenance • Smooth and gentle product transfer to and from the scale • Straight-forward and hygienic construction • Dynamic calibration
This single-lane belt scale model 1800 was developed to meet our customers´ increasing demand for highly reliable and accurate weighing - even in challenging production environments.
ways be centered on the scale when running. The weighing machine has an adjustment feature that makes it easy and fast to position the belt correctly. It only takes a few seconds to set it.
The high accuracy achieved on this belt scale is a combination of intelligent design and effective software solutions. High accuracy weighing is essential for correct sorting, grading, batching and packing. It reduces the economic impact of a high give-away or repeatedly underweight packing. The standard deviation is as low as 0.3 gram* meaning that 68% of all weighing results for a specific item will be within the average variation value of +/- 0.3 g. Put differently: Up to 99.7% of the products will be within a +/- 1 gram variation.
The product sensor is fully fixed and yet it is adjustable. In its protectable bracket it cannot be pushed or turned out of position. Only by using a standard tool it can be height adjusted to get the best possible detection of the products running on the scale.
The size of the weighing plate is configurable ensuring maximum capacity given a specific product length. In fact, you can easily replace the weighing plate depending on product length and thus gain capacity. A small nose bar radius ensures smooth and gentle product transfer to and from the weighing machine in order to guarantee high capacity. For accurate weighing and longer belt life, the belt must al12
Sensor positioning
Belt adjustment
Poultry newsletter
e x pert to e x pert Recommended daily routine before production start • Start up the weighing unit and wait a minute for it to stabilize • Test that the tare weighings do not show abnomalies according to calibrated off-set • Run an item with known weight over the weighing unit and check that the registered weight does not differ significantly (depends on the specific weight type, water on belts, temperature differences or other external factors) • If any abnomalies are noticed the weighing unit should be inspected visually to see if anything is stuck or touching the unit. The belt should also be checked to ensure that it is intact • If the weighing unit is mechanically okay, a calibration should be performed. B’Logic® Grading software shows the date and time for the lastest conducted calibration and can indicate if weighing problems are due to lacking calibration • Keep daily or hourly records of weights to be able to document weighing accuracy
The belt scale is especially developed for high risk areas. The open and straightforward construction with few horizontal surfaces makes it easy to clean. The particularly developed belt with an even and smooth texture is easy to clean thoroughly and only 4 simple steps are required to remove it:
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1. Push up belt tension 2. Take out the reversing roll 3. Open top cover 4. Remove belt
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* The standard deviation depends on in-feed, product characteristics and enviromental impact
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Poultry newsletter new i nt u i t i ve grader s oftware
B’Logic® Grading
Key benefits:
• Complete real-time insight into grader production • Highly configurable views to fit specific user requirements • Aggregating batches from multiple lines reduces give-away • Easy and flexible job execution
The platform that our own developed and well-tested weighing algorithm represents is the basis for our newly released and next generation of BAADER LINCO grader software, B’Logic® Grading. The new software is built upon an innovative dashboard that allows for highly intuitive data presentation and user interface. The dashboard can be monitored on an office PC or directly on the shop floor. It can be configured to fit specific user requirements and to highlight important key performance figures, e.g. give-away, speed and throughput. When a particular grader process should be monitored, the software user can choose to see details in a subdivided dashboard. New features on our B’Logic® Grading software are: • Multiple grader view on the dashboard with key performance figures that allows for prompt reaction in case of inefficient production • Multi-grading having more lines feeding one gate in order to reduce overall give-away • Job controlled production guiding the correct amount of products to subsequent in-line processes 14
Grader production jobs can easily be created, started, finished, archived or reprioritized in the job management part of the grader software. It has been of great importance to us that our software reflects the ever-changing conditions that our customers face every day. Therefore all details for the selected and already running jobs objects to possible changes are presented in a pop-up box so they can easily be modified by the user. The production monitoring is highly configurable in order to adapt to specific user requirements.
B’Logic® Grading interfaces to our B’Logic® Label Composer
which is our label set-up software, meaning that the user can easily select the label to be used for a specific grader job. In the report view the user can find a list of printed labels which can be re-printed if necessary – and he can choose to print them on another label printer if the previously chosen printer is not available anymore. The software has a reporting feature in order to provide exact and fast production reports on specific grader production or performances, production time periods, product types, production events etc. Reports consist of both table and graphical views and the user has the option to print all reports.
Poultry newsletter s i mpl i c i t y i n label de s i gn
B’Logic® Label Composer
Key benefits:
• Fast and flexible label creation • Multiple label purposes and minimized label maintenance • New standards for fast printing • Easy label search function
Our newly released B’Logic® Label Composer is an officelocated software specifically designed to create labels to the food industry. The result is extremely user-friendly label design software that focuses on avoiding repeated label designs and laborious creation procedures. When creating a new label the user works directly on a canvas which means that he will see the exact design of the label as it will be printed on the label printer. An intelligent data link function allows the user to insert variable information on the label. The software is installed with predefined links which draw the correct information from the system, e.g. product name, traceability code etc. This unique feature reduces the use of static text and ensures that the same label can be used for multiple products and customers. Thus the creation of new labels and the maintenance of existing labels are highly simplified. Print speed is critical to reduce errors and unproductive waiting time. BAADER LINCO has developed a direct printer driver to obtain optimal printing speed without queuing labels. Label queuing is often the main cause for incorrect labelling
of the products. The label software has a built-in barcode generator and a variety of barcode types can be composed and inserted directly when creating a new label. The B’Logic® Label Composer also offers the possibility to add QR codes to the label - a unique promotion and information tool to be used by the poultry processor or the distribution channel: Reference to a website, presentation videos, cooking recipes, traceability etc. 15
F R O M
B A A D E R
L I N C O
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W W W . baader . com
S h ow s aro u nd t h e world
Meet us here in 2014
Polagratech, Poland 28 - 30 September IPPE, Atlanta 28 - 30 January
CFIA, France 11-13 February
Agroprodmash, Moscow 6 - 10 October
VIV Europe, Utrecht 20-22 May VIV, China 23-25 September
Gulfood Dubai 23 - 27 February Saudi Agriculture 8 - 11 September
FoodTec, Brazil 5-7 August
Poultry India, India 26-28 November VIV, India 23-25 April
Avícola, Argentina 13-15 May
LINCO FOOD SYSTEMS A/S DK-8380 Trige • Denmark Tel +45 86 23 14 55 • Fax +45 86 23 14 44
[email protected] • www.lincofood.com
Illustrations and dimensions are approximate and not binding. Subject to design changes in the interest of technical progress. Actual scope of supply is specified in our quotations and order confirmations and may differ from descriptions and photos in this leaflet. Attention! For the illustration of 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 must be utilized and/or observed. (Protective panels and safety guards removed for photograph)
