Focus on China STORK POULTRY PROCESSING. Customer cases from all over the world. Where trends become opportunities > 8

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1 INSIGHT STORK POULTRY PROCESSING March 2012 Focus on China Customer cases from all over the world Where trends become opportunities > 8 Feet processing: a fully grown part of the primary process > 11 The new Marel Multihead Weigher IQF Poultry > V O L U M E 1

2 Range of chilling options extended even further CONTENTS Taking the worry out of service Range of chilling options extended even further Velskaya leader in fresh market Changes in the Russian poultry market AMF-BX breast cap filleting system updated The Marel Research Team Dakota Provisions Where trends become opportunities Trend: product quality & safety Feet processing: a fully grown part of the primary process Marel Stork in China A systematic approach to solving evisceration challenges The Leg Dressing Module Two new milestones in Spain Sharpened focus on Argentina Marel weigh price labellers Multihead Weigher IQF Poultry Poultry Exhibitions 2012 Worldwide Taking the worry out of service Recent growth in our industry underlines the importance of good service. Guaranteeing each day s production is becoming ever more important for many poultry processors. Above all, it must always be possible for our customers to supply their customers in time. Contracts leave little room for deviation and the financial risks are high. Within the service department, we work in different ways to support you in your objectives. Again and again, important departure points for us are low cost of ownership and optimizing throughput and yield. It is for this reason that we focus on optimum availability of all your equipment when designing a new machine. From there, we take into account optimum accessibility for maintenance and overhaul. Our team of specialists aim for the most maintenance-friendly design possible. It must be possible to carry out overhauls quickly. Predictable maintenance costs Another way in which we can support you even better is to give you a view of the preventive maintenance and overhauls which your installed base will need through a Service Level Agreement. From our own experience we know that preventive maintenance helps to minimize downtime and maximize the equipment s life. Our preventive maintenance programs will tell you in advance, at machine level, what the maintenance intervals are and the associated costs you can expect. For complex plants which are in production for many hours a day, such a contract is almost indispensable. A service contract will also help to lower cost of ownership. Many personnel changes and more complex processes Our training courses also contribute to good support. When a project is started up, instruction is, of course, given to staff. With staff turnover and increasing production flexibility, however, there is more and more need for focused instruction and training on-the-job. We offer training courses either on-site or at our training centers. We are making additional significant investments in this over the coming period in order to make your learning experience even better. Our new training center in Boxmeer (The Netherlands) will soon be ready. Partners in technology The objective of our range of service products is to take the worries from your shoulders. One way of doing this is by having a strong local presence in more and more markets. In several local offices (like the USA, China and Russia) we are further expanding our service teams strongly and staff is being trained almost continuously. In this way we create teams that know our local customers and the region even better and as a partner in technology they will provide the best possible support. I wish you a pleasant read. Gerrit den Bok, Service Director Marel Stork Poultry Processing How a fresh broiler is chilled has a substantial influence on its shelf life, presentation, eating quality, and most importantly for the processor, its final yield. Air chilling technology is therefore about much more than just reducing temperature. It must also address microbiological and weight loss issues. The process should result in broilers at the correct temperature with no frozen wings or neck flaps, superficially dry but with any moisture loss kept to an absolute minimum and of a color attractive to the end consumer. Marel Stork Poultry Processing has many years experience of chilling poultry in-line and offers a wide range of solutions. Single stage systems In-line Downflow and InfraChill tunnels are single stage air chilling systems. Downflow tunnels are multi-tier, typically three or four tier. InfraChill is a single tier system with a larger footprint but a shorter chill time as air is blown positively onto broilers through ducting. In both cases, chill times will depend on product weight and the final broiler temperature required. Which system is chosen will depend on the customer s own situation and requirements. Plus technology Downflow and InfraChill systems can be equipped with Marel Stork Poultry Processing s well-researched and well-proven plus technology. The technology keeps weight loss to a minimum and ensures optimum bacteriological quality and product presentation. It consists of a number of cabinets for applying a film of water to broilers at set intervals during the process. The film is applied to all external and internal surfaces and/or to external surfaces only. How, how often and at what points during chilling the film is applied will depend on customer end product requirements. In-line maturation chilling Some fifteen years ago, Marel Stork Poultry Processing pioneered and installed its first in-line maturation chill system. Increasing demand for tender breast fillet products, a trend which has continued unabated since, had given an impulse to the search for a cost-effective alternative to time, labor and space-consuming maturation off-line. The system, which for full maturation effect should be run together with the company s RapidRigor in-line electro-stimulation technology, has two stages. A first stage shock chill using very cold air at very high velocities is followed by a much longer second stage where broilers are chilled to the required end temperature using warmer air at much lower velocities. Plus technology is used throughout to minimize weight loss and optimize product presentation and shelf life. The result is a breast fillet as tender as if it had been matured for many hours off-line. Since installation of the first system in 1997, many plants have installed the technology, a large number of which are now handling 10,500 bph / 175 bpm and above. Problems of growth Ever higher line speeds in processing plants worldwide are witness to poultry s continuing growth. Growth, however, comes with its own set of problems, among which is often a lack of space to expand to accommodate the additional equipment necessary for an increase in line speed or broiler weights. This often makes it difficult, if not impossible, to extend an existing air chilling installation. Because this forces the system to run above its design capacity, it will inevitably compromise final product quality. Presentation, shelf life and yield will suffer. A new technique to the rescue For such situations Marel Stork Poultry Processing offers its in-line immersion chill system, which would be added as a first stage to an existing Downflow, InfraChill or maturation chill tunnel. The system makes use of water s ability to chill product up to 50% more quickly than air at the very beginning of the chill process when the broiler is still warm. Dwell time in the immersion chill stage will depend on each individual situation but is unlikely to be longer than 10 minutes. The immersion chill system consists of a single or multiple tanks filled with cold water through which broilers are transported on a chilling shackle. Water in the tanks is kept chilled using a cooling agent circulated through integral heat exchangers. Falling film equipment chills any make-up water. Tanks can be installed on the floor of an existing air chill tunnel making use of existing space. In some countries end products must be of a particular color. If a whiter bird is needed this can be achieved by bleaching during immersion chilling. After leaving the immersion chill stage broilers pass into the original single or two stage process. Technology already in place can be used to fine tune the system to give an end product which meets all required parameters. The right solution for every occasion Effective chilling is about much more than just reducing temperature. For the best results, each situation should be handled individually and the appropriate technological mix chosen. In this context, adding immersion chill can be a very interesting option for those processors wishing to extract more chilling capacity from an existing chill tunnel footprint and demonstrates, yet again, Marel Stork Poultry Processing s ability to offer the right chilling solution for every occasion. 2 3

3 Velskaya leader in fresh market Building a successful future together with Marel Stork Poultry Processing The Velskaya Poultry Factory lies about 750 km / 466 m to the North East of Moscow. This year the Company, which employs over 500 workers and has a line speed of 6,000 bph / 100 bpm, will produce approximately 22,000 ton / 48 million pounds of a variety of poultry products. Choosing Stork Poultry Processing in 2010 was the start of a period of growth. Both the quantity and the quality of Velskaya s production have increased enormously. Under the enthusiastic leadership of Miss Oxana Lukinyuk Velskaya is investing on a continuous basis in increasing the Company s production. In the space of just one year Velskaya has become one of North-West Russia s leading poultry processors for the fresh market. Production has increased almost fivefold. The many flowers on Oxana Lukinyuk s desk are proof of a successful first year as director. Improved evisceration department: the basis for quality In the first phase of the improvement process Oxana and her staff, together with Stork Poultry Processing, saw the focus needed to be on improving the evisceration department and on updating the entire cooling installation with a full Downflow+ line. This led to a significant improvement in product quality. At the same time, production was scaled up from 4,000 bph / 67 bpm to 6,000 bph / 100 bpm. The Nuova eviscerating system, together with the VOC (combined vent cutter and opening machine) form the heart of a perfect evisceration process, enabling Velskaya to conquer the fresh market. Portioning Besides the shift to the fresh market, Velskaya is experiencing increasing demand for chicken portions. Oxana Lukinyuk explains: We now produce about 50% whole broilers, and 50% semi finished products. This is shifting. Consumers demand more and more chicken portions. Within a few years the ratio will move to 70% cut-up products. We have started producing further processed products and at the end of 2011 we commissioned a ready product department producing up to 25 tons/ 55,000 pounds of different sausages each day. Each month we want to launch a new poultry meat product onto the market. Growing with Stork Miss. Lukinyuk continues: We are now a large, stable and strong company marketing quality products everyone knows and wants to have. We are positioning ourselves more and more as a producer of top class fresh products. To support this we are planning to launch two new brands of economy and premium class product in the coming period. To reach our growth and quality targets, we work closely together with Marel Stork Poultry Processing. They have the right experience and knowledge in poultry meat processing and deliver the quality equipment we need, especially for our fresh concept. The fact that Marel Stork Poultry Processing is doing so well in the Russian market is not surprising. It is the Company s philosophy of striving for high quality fresh end products with a perfect evisceration department and a well controlled pre-chilling process as the basis for this that suits the Russian market. It s a market making the change to fresh products with consumers expecting ever higher quality. Second phase Now that the evisceration department and cooling processes have been updated, Velskaya is currently working on the next phase: improving and automating the weighing and grading of products and changing internal logistics in their entirety. While maintaining flexibility, the Company is looking for a higher degree of automation and optimal product flow. That s the only way to guarantee product quality and improve production efficiency. The perfect grading, weighing and logistics solutions available from Marel Stork Poultry Processing are now an integral part of the overall project. Marel offers their customers the convenience of a single source for equipment and systems to meet all their processing needs while raising the quality and value of their products at the same time. Trust and growing together Velskaya is a customer continuously striving to improve quality and incorporate new developments and Marel Stork Poultry Processing, with its strong innovative character, is just the right partner to make this happen. The common goal is therefore to build a lasting relationship and to work in partnership. Miss Oxana Lukinyuk says: Right now we are working on a new phase. To me the most important word is trust. We trust Marel Stork Poultry Processing and are convinced of the quality of their equipment. Besides that, the employees are very pleasant to work with, are easily accessible, respond quickly and are very knowledgeable. They always find the right solution. We are working together toward a great future. We are working together toward a great future! Changes in the Russian poultry market Marel Stork Poultry Processing offers perfect solutions for the production of fresh chicken products. Changing customer requirements, up-scaling, increasing automation and striving for better quality. These are all developments which are currently being addressed by the Russian poultry market. They are related to falling imports, to the boosting of local Russian production and even to increased export potential for the future. The role Marel Stork Poultry Processing has played in this area since 1964 offers interesting opportunities for every poultry processor and further processing processor. Below is an overview of various developments. We can see various developments taking place within the Russian poultry market. In the regions around the major cities, such as Moscow and St. Petersburg, up-scaling is an important topic. Large companies often focus on several protein groups and produce a very wide range of products in large quantities. To them up-scaling and increasing efficiency will also be important developments in the coming years. We can also see regional players who focus on supplying the region, often at lower production capacities. Across the country, the fresh food market is on the rise and increasing numbers of whole broilers are being cut up. The market for convenience products offers all manner of opportunities for the years to come. Striving for higher quality Striving for better quality is an essential topic. As a result of the goal of becoming self-sufficient, Russia has increased production levels and reduced imports. Taking into account the possibility of increasing exports to Europe, quality is becoming an increasingly important topic. Supplying good quality live broilers is of course an essential step but with the vertical integration taking place within Russia, this is a manageable process. The next important steps will be how properly to set up the various sub-processes. Fresh Russian products: increasingly important All of this is also related to changing demand. Consumers increasingly want fresh products; the Russian consumer was traditionally used to frozen chicken. It is now possible to offer a continuous supply of really good, fresh chicken Russian chicken. Marel Stork Poultry Processing s knowledge and technology make it easy for Russian processors to optimise product shelf live, which is a crucial parameter when producing fresh product and especially when supplying it to remote regions. Improved chilling as a quality stimulus Marel Stork Poultry Processing offers various technologies for chilling products in-line quickly and efficiently with excellent yield control. The starting point and the objective is a perfectly fresh product with a long shelf life. The Stork Downflow+ chilling technology is a proven everyday success in Russia. Customers praise the way in which the quality of the end product can be adapted to market requirements whilst ensuring optimum yields at all times. A Marel Stork Poultry Processing chilling line makes optimum product quality possible and increases sales opportunities. Proven track record for all processing speeds Continuing to process good quality fresh products at a lower cost per broiler can be an important reason to increase production capacity. Stork Poultry Processing offers solutions for all desired production capacities. With many successful upgrade projects in all corners of the world, Marel Stork Poultry Processing has the right knowledge and experience for processors who are in the phase of starting or upgrading their production. When a poultry processor wants to increase his capacity, the modular processing line can be modified and extended without having to invest in a complete new line. Unique high speed processing Marel Stork Poultry Processing allows birds to be processed at high speed, up to 13,500 broilers per hour on a single processing line, whilst maintaining the high yield and low COO, typical for Stork Poultry Processing equipment. At the same time, all process components are perfectly tuned to each other. The supply of live animals, stunning and slaughtering, eviscerating process, chilling and grading and distribution line can all be designed for a speed of 13,500 bph. An important element, central to ensuring a good quality end product, is the Nuova 24 eviscerator. Together with the new VO-20 RS opening machine and the new Vent Cutter RS 16 it forms the beating heart of a modern and efficient eviscerating department. Duck meat is becoming popular. Portioned and de-boned products lead to higher margins In Russia, the market for portioned and de-boned products is on the increase. This leads to opportunities for adding more processing value compared to selling whole products. Marel Stork Poultry Processing offers the most extensive range on the market of solutions for automated portioning and de-boning. With its famous ACM-NT cut-up line and unique automated transfer to the leg deboning system, its AMF-BX breast cap deboning line, its unrivalled FHF-XB front half filleting line and its smart cutting solutions for accurate batching, Marel Stork Poultry Processing supplies the most profitable solutions. Turkey, duck and geese processing Increasing demand for turkey and duck meat in the Russian Federation is yet another development. Over the years several innovative new developments have been launched for the processing of turkey, duck and geese. Marel Stork Poultry processing is ready to fulfil all market needs using the latest technologies for live bird supply, de-feathering, evisceration, chilling and portioning, all at the highest possible processing capacities. Marel Stork Poultry Processing: Your partner for all technologies Marel Stork Poultry Processing is known around the world as a full-line supplier of high-quality solutions for the processing of broilers. We offer solutions for all process steps, all required production capacities and all levels of automation. Together with our highly valued customers, we work daily on solutions making it possible to achieve the very best, tailor-made to the requirements and circumstances of the customer. Marel Stork Poultry Processing has operated in Russia for many years tangible proof of the success and enthusiasm with which the company is able to make its contribution to the development of the Russian poultry market. 4 5

4 AMF-BX breast cap filleting system updated yet again Control by menu makes for even higher yields Dakota Provisions Versatility is key in the world of turkey production Marel Stork Poultry Processing is proud to present control by menu for its AMF-BX breast cap filleting system. The control system leads the way to consistent high performance and makes possible the easy fine-tuning of the settings of your filleting system to the type and weight of breast cap being handled. Quickly and simply, you will be able to lift both the quality of your end products and the yield of your whole system. Since its launch, technical and technological refinement of the AMF-BX breast cap filleting system has been continuous. The number of end product options has become ever larger, the number of manual operations fewer and the cuts possible more complex. As a result, the system s yield has kept on increasing. Control by menu, available as a conversion kit for your existing system, is the next step on the road to a completely updated and improved filleting line. Optimize settings centrally for higher yields In one step, via a touch screen menu, you can now adjust module settings with ease. If, for example, you need to start processing a different average weight or a different The Marel Research Team Linking fundamental research to practical applications Last autumn, Marel s Research Team in Boxmeer (The Netherlands) once again played host to a group of 30 students from Wageningen University, also located in The Netherlands. The day in Boxmeer forms part of the annual Master of Sciences Meat Technology Course and has been highly valued by students for the past 6 years. Several Meat Scientists from the Marel Research Team shared their knowledge of fundamental meat technology and actual research topics in lectures and practical sessions. The students were impressed by the range of topics covered by our experts and by their in-depth knowledge of the various aspects of meat technology. Moreover, the equipment available in the Boxmeer DemoCenter provides the opportunity of conducting full scale experiments in further processing. The translation of fundamental knowledge into practical experiments in the afternoon gave the students a lot of fun as well as an insight into possible application areas for the research topics. Research is key Marel believes that it is important to understand the underlying mechanism of why things work? before translating knowledge into equipment. This includes, for example, understanding nerve and muscle physiology pre- and post mortem, modeling chilling/heating curves, meat flow behavior and coating meat products. Only a thorough understanding of the principles and mechanisms makes possible the development of transformational breakthrough technologies such as Multiphase CAS (Controlled Atmosphere Stunning) and the RevoPortioner; both examples of completely new approaches based on years of research. type of breast cap (a different breed of broiler), you can now enter this information. All relevant modules will retune to the new situation. What you are now able quickly to optimize are adjustments such as the moment a blade begins to cut and the length of a cut. The quality of your filleting process will improve as a result. You will achieve higher yields and end product quality will go up. More consistent performance As many pneumatic connections have now been replaced by PLC controlled sensors, there are now fewer components in the line sensitive to wear and breakdown. As a result, performance of your AMF-BX filleting system will stay for longer at a higher level; maintenance costs will go down. Control by menu will also give you a view of the number of hours the line has been running and you will be able to judge when maintenance is due. You can also see whether sensors are working as they should. Control by menu is available as a conversion kit for your existing AMF-BX breast cap filleting system. It is one more step towards low cost top-class filleting. This year we will be launching yet another new development which will lift the system s added value still further. Contributing to the industry Conducting fundamental research epitomizes clearly Marel s long-term approach and commitment and is a core asset of the Innovation Team. Moreover, research is often conducted in close collaboration with universities and research centers in different countries. Several members of the research team have a worldwide reputation within the industry and scientific community and are members of scientific boards and working groups. This is also reflected by frequent invitations for presentations at international congresses and symposia around the world. COMPLETE COVER The Marel Research Team consists of a group of international scientists with professions ranging from biology and agricultural sciences, process and mechanical engineering to food sciences. Together they cover the complete supply chain from slaughter to further processing, linking fundamental research to practical applications. l-r: John Hott (Plant Manager Raw Operations), Ken Rutledge (President/CEO) and Chet Coolbaugh (Operations Manager). You need to have versatile processing options to handle the array of turkey products today s consumers want. And, as a supplier to one of the world s most dynamic and steadily growing protein industries, you need to have the versatility in your expertise to innovate systems for processors who demand a customized solution to meet their needs. Marel Stork Poultry Processing has developed a line of turkey equipment especially for the turkey market to provide customized solutions based on the needs of the market. Dakota Provisions was founded with a focus on the family farm, a commitment to quality and the dedication to building a world-class facility in Huron, South Dakota. As a greenfield project in 2005, the systems they chose to put into their world-class facility had to be able to deliver on the company s number one objective: Leading the industry in food safety. We reviewed and assessed available equipment and made our decision based on the best available option, stated Ken Rutledge, President/CEO. We were looking for someone to come in and put a system together for us and I liked what I had seen in other Stork installations. They chose Marel Stork Poultry Processing to partner with in providing solutions for first processing in their new facility. Food safety As the company s number one objective, processes that provide advantages in food safety were part of the design of Dakota Provisions system. Their equipment choices needed to deliver hygiene advantages by preventing cross-contamination. Marel Stork Poultry Processing equipment utilizes innovative designs and processing knowledge to deliver equipment that maximizes efficiency while preserving quality and minimizing potential contamination issues. These advantages in hygiene made the system a natural choice to support Dakota Provisions food safety goals. With any purchase, the equipment has to be very accessible and easy to clean. It has to be primarily stainless and resistant to chemicals, Rutledge noted as Dakota s minimum requirements even to be considered. And, there can be no areas you can t reach to clean where bacteria can be trapped. Dakota s Plant Manager Raw Operations John Hott added, We were looking for an automated system. Any time you add automation it decreases the handling and takes human hands off the product. That helps with cross-contamination issues. The design and function of the three-point suspension system they chose have supported their food safety goals as well: The three-point positions the broiler ergonomically and extends the body so there is not as much pressure on the gut pack. Together with the fact that the viscera pack hangs below the broiler, it reduces the amount of fecal material you have running out of the broiler and, therefore, you have less contamination, said Hott. Least cost production Continued volatility in uncontrollable, variable costs is a driver for producers like Dakota to find ways to take cost out of the system. Cost of ownership is an important consideration in any Stork Poultry Processing innovation. We wanted to install a proven system with a company that had proven support, both parts and people, said Rutledge of their goal. We wanted the most cost efficient system to allow the least cost production. The Stork Poultry Processing first processing equipment they chose was designed to maximize efficiencies, save labor and provide low cost of ownership. Controlling costs is very important to us, but as a plant that competes nationally with other plants, our goal is to be the best. said Hott. He has found that the three-point system is a particular benefit in this area as well. He pointed out that, The three-point is very reliable. It runs every day, not like some equipment that you have to worry about. It helps us to become a low cost producer by doing the work that otherwise you would have people in there doing. He went on to add that the way the broiler is laid out in the three-point also contributes to their processing efficiencies by reducing labor in reprocessing. Our reprocessing rate is below the industry average. Dependability after the sale Marel Stork Poultry Processing is built on a value of Partnerships with Customers. That partnership is supported by a commitment to providing support and expertise beyond the initial sale and installation. Our relationships with customers are a lifelong responsibility. We wanted service after the sale. It s easier to manage through primarily one complete system, noted Rutledge on choosing Stork Poultry Processing for their system. Dakota has found that a key to their system s excellent performance has been their strong commitment to a preventative maintenance program. It s turnkey. The system starts up every morning. It s very easy to maintain and cost effective, said Hott. He also credits the simple design of the system for its dependability and reliability. He noted that the machines are easy to learn and adjust which has allowed their staff to learn to support them quickly and effectively. You can tell the machines were built for a turkey plant, Hott said. You need strong, tough, dependable equipment in here. The system lives up to that. Dakota Provisions system is performing excellently said Rutledge. Overall, honestly, it has exceeded our requirements. We are very pleased. 6 7

5 Where trends become opportunities Trend: a growing world population Protein consumption is increasing alongside the growth in the world s population and its urbanization. In many markets poultry meat is playing an ever more important role. In many areas we are seeing a solid up-scaling in the production of chicken items. We are also seeing increasing degrees of automation, which are witness to the quest for more efficient processes and better end products. Marel Stork Poultry Processing supplies killing and processing lines for throughputs of up to 13,500 bph. / 225 bpm. The German processor Emsland Frischgeflügel premiered this in In the meantime, there is interest from customers worldwide in processing at this high speed. GP container live bird supply system Perfect logistics are ever more important at higher throughputs. We begin with the supply of live chicken from the grower to the processor. It is here that the GP container supply system offers the best solution available in the market. At a processing capacity of 13,500 bph. / 225 bph of 2.5kg. / 5.5 lb. live weight just 56 containers per hour will see the system making easy work of production, while treating the livestock gently and well. After being placed on the system, containers (if necessary, two high) are unloaded fully automatically, washed, disinfected and re-stacked. With loose crates at the same capacity you would have to load, unload and clean approximately 1650 crates per hour. Quite apart from the number of employees needed, it would also not be the best for bird welfare. New Reference Series Vent Cutter and Opening machine Another important link in high speed processing is the evisceration line. Stork Poultry Processing has developed an all-new opener, the VO 20-RS, for the highest line speeds. This machine, launched in 2010, is proving its strength to many customers on a daily basis and, when combined with the VC-16 RS vent cutter and the Nuova eviscerating machine (24 units for 13,500 bph. / 225 bpm.) it lays the perfect foundation for subsequent processing. Even at this high speed, the quality of automatic harvesting of all those valuable giblets is first-class. At high speeds getting through the day s throughput is essential. You will want to optimize up-time at all times and your line should run well for long periods. Your customers make ever higher demands and contracts leave little play room. New Equipment monitoring With Equipment Monitoring you get on-line and real-time clearly presented information on the technical function and performance of your equipment. Warnings give you a quick insight into variations within your process, so that you can take timely action. In the case of an alarm you can see quickly where there is a problem. Contract for preventive maintenance A service contract for preventive maintenance gives you a view of when a given machine needs preventive maintenance together with an indication of costs. The correct parts will then be sent in good time in the form of a maintenance set. Good preventive maintenance will ensure that your installation runs optimally for as long as possible, giving high yields and the highest possible up-time. Your total cost of ownership will go down and costs will be predictable. Trend: new products On average, people are spending less and less time on preparing their meals. The popularity of convenience food is growing strongly too. More and more products are being offered in small portion sizes, pre-cut, seasoned, marinated and quite often pre-cooked, sometimes as a component of a whole meal. Increasingly often products are ready to cook or ready to eat. The consumer also needs a lot of variety and is looking more often for regional and healthy products or products with a more extreme ethnic taste. Retailers compete ever more aggressively for their customers favor with new product ideas. Besides their own brands, exclusive lines are popular as an alternative to eating out. We supply a large number of machines for cutting de-boned chicken meat. These are flexible solutions which quickly and accurately cut a fixed weight, fixed length or specific shape from breast or thigh meat. Examples of end products are strips, diced chunks, trimmed fillet shapes with a fixed weight or so-called minute fillets. (thin cut fillets). The SmartSplitter The SmartSplitter slices poultry fillets horizontally into portions of a desired height. It is available in both single and dual lane versions. The product belt is easily adjusted up or down for the desired thickness. The result is a very We grow with you The nub of the Marel Stork Poultry Processing approach is, wherever possible, an automated, in-line process modular in make-up. Besides solutions for high speeds, we also offer solutions for low capacities where, to start with, certain operations can be done manually. At a later stage, increasing amounts of automation can be introduced and the modular line extended. We grow with you as your production increases. When you need more automation, you can add modules to your existing process. We have built up our many decades of experience working with local markets. High capacity processing requires more production control and management information. high degree of accuracy on the finished product. The dual lane SmartSplitter can operate with different height settings on each lane. I-Cut 22 The I-Cut 22 is an advanced dual-lane PortionCutter designed to cut poultry products accurately into fixed weight or length-specific shape with minimal giveaway. The PortionCutter operates at very high speed and gives top performance with up to 1,500 cuts/minute per knife per lane. The I-Cut 22 PortionCutter comes with a 45 degree cutting option. This makes it easier to achieve a natural look on products such as fixed weight chicken breasts. High speed portioning Great accuracy - resulting in minimal giveaway Small footprint Hygienic and easy to clean Template Slicing Machine The TSM Profiler is an innovative template slicing-machine designed to produce identical portions for the foodservice industry. The machine produces uniform, valueadded portions with optimal utilization of fillets. I-Cut 36 The I-Cut 36 is one of Marel s high-speed, high-precision PortionCutter product range and is ideal for cutting products to a fixed weight or length. The high accuracy of the machine results in minimal giveaway, thereby providing excellent profit opportunities. The I-Cut 36 operates at high speed, with a top performance of up to 1,000 cuts per minute. The I-Cut 36 is extremely flexible with features that include a 45-degree cutting angle, ensuring that the cut products look natural. High-speed portioning High accuracy Minimal giveaway Flexible to use cutting angle easily changed Hygienic, easy to clean Consistent portioning - reduced trim Portions of identical weight and shape Great accuracy Labor saving StripCutter The StripCutter is an easy-to-use portioning machine that cuts fixed-sized portions at high speed. The portioning machine provides a range of cutting options as the StripCutter can cut products into strips, splits, steaks or diced portions. Versatile portioning machine for many applications Phenomenal cutting quality High throughput Only one operator required Maximum profit thanks to rapid payback Marinating all kinds of bone-in and de-boned products either wet or dry is very popular. This gives interesting possibilities in almost all markets. New tastes and applications are being thought up all the time. ValueDrum The ValueDrum marinates small batches in line, either wet or dry, larger or smaller products, with or without bone and with or without additives such as onions or paprika. The ValueDrum is modular and can be extended with extra segments should a faster process time or larger volume be necessary in the future. Uniform distribution of additives Smaller batches give less product damage Short process times Reduction in labor and materials costs Longer product shelf life Batches of product are easier to follow It is always a challenge for poultry processors to connect with these developments. It is becoming ever easier to reach a heavier live weight in a short period of time whereas consumers often want smaller portions. Produces products of uniform thickness High throughput with accurate cutting quality Easy to operate with low maintenance cost Small footprint The SmartSplitter 8 9

6 Trend: Product quality & safety The demands being made on food safety are increasing all the time and complete traceability is becoming more and more important. Fast food chains, food service and, to an increasing degree, the large retail organizations want bone-free products more and more often. Consumers are also finding quality more and more important. Fresh, local or unprocessed products are more and more popular. For all these aspects Stork Poultry Processing offers various solutions. Feet processing: a fully grown part of the primary process For a long time now feet have not had to be waste. The popularity of feet and paws is still on the increase. Different producer countries are exporting to China and other South East Asian markets. Prices for properly processed feet are such that investment in a feet processing system is an interesting option for many processors, particularly if this is Marel Stork Poultry Processing s updated system. Processing feet is a fullyfledged part of the in-line primary process. SensorX: no bones, no worries Thanks to advanced detection technology and software development, SensorX automatically identifies bones and other foreign objects in poultry meat using advanced X-ray technology. With its unprecedented detection capabilities, SensorX is now the global market leader in automatic poultry bone detection. SensorX commonly achieves a 99% detection rate on calcified bones larger than 2 mm. in their smallest dimension with false positives below 3%. Scanned products are safer and have a higher value. What is more, scanning products reduces costs. You have less rework and no claims. Fillet handling solutions: higher quality The various inline fillet handling solutions available from Marel Stork improve your filleting yields and, by providing a more hygienic production environment, give you better quality products. Products are presented uniformly to operators, who then need concentrate on fewer different tasks. Only those fillets which have to be trimmed are touched by hand. Any visible bone remnants are removed. The amount of any manual work needed also goes down. You need fewer operators to achieve the same level of production and more consistent quality. With a fillet handling solution you will be able to save up to two employees per line depending on your production environment and product requirements. Fillets are positioned automatically at various points in the process without having to be touched by human hand. Different smart handling belts have been developed to achieve this The out-feed from the SensorX is a flow of checked, scanned and, if necessary, trimmed products, ready for the next step in the process. INNOVA Innova provides the complete IT solution when it comes to optimizing profits and overall production performance. Innova covers the complete value chain in the production cycle, from reception of supplies to product dispatch, providing all key performance indicators (KPIs) for each stage and traceability from door to door. Innova closely monitors and controls critical KPI s in real-time. This can include yields, throughput and efficiency, giveaway and loss of sales, quality, stock levels and movements, traceability and profitability. Innova is based on a modular design that provides maximum flexibility, a solution for all from small operations through to plant-wide systems. Processing feet is a fully-fledged part of the in-line primary process. SensorX Terminal With its unprecedented detection capabilities, SensorX is now the global market leader in automatic poultry bone detection. Fillet handling solution Components of the system are as follows: Scalding Feet are conveyed by a turning screw to the end of the scald tank. They are (hard) scalded with water at approximately 60 C / 140 F. Water is heated either by direct steam injection or indirectly using hot water and a double wall. Striving for high value by-products With Marel Stork Poultry Processing s updated feet processing system you will be taking a further step towards marketing your broilers in the truly best way. Next edition Trend: Sustainability For those processors operating at high throughputs, we have now introduced an updated, extra-large, energy efficient scalder, the XL. This is suitable for the highest capacities, 13,500 bph. / 225 bpm. Scald water is heated using hot water circulated inside a double wall. A supply of steam is therefore not necessary. After scalding, feet are transported by a screw to the peeler for removing the horny layer of skin. Feet peeler The horny layer of skin is removed in the feet peeler using rotating plucking (picking) fingers. For optimal peeling, hot water is added at the beginning of the process. The cold water supply is installed at the back of the peeler. The layer of horny skin is flushed away via a central drain. Recently we launched a feet peeler for high capacities. Feet chiller Feet are now ready to be chilled. This happens in a short period of time in a tank of chilled water with a screw or in a paddle chiller. Once chilled, feet can now be packed. If necessary, feet can first be sorted and assessed for quality. Marel Stork Poultry Processing supplies screw chillers and paddle chillers in various sizes. Adding as much value as possible to each bird is part of Stork Poultry Processing s philosophy. The feet processing system is accurate, automatic and fully in-line. Production can be controlled and monitored using INNOVA software. What is more, the system has an attractive payback time in a market for edible feet and paws, which continues to grow. For more information contact your Sales Manager. The feet processing system is suitable for processing even at high line speeds and consists of a number of modules, allowing the ideal combination to be put together for each customer. Feet are unloaded from the killing line. If necessary, feet can be cut to the required length with part of the tarsus. They are then conveyed to a scalding tank. After scalding, plucking(picking) fingers in the peeler remove the layer of horny skin. They are then chilled and discharged directly into crates or onto a sorting table

7 Marel Stork in China Strong local presence the basis for successful growth In recent years, Marel Stork Poultry Processing has substantially expanded its activities in China. After an initial period when projects were coordinated from the Industry Center Boxmeer, with its two offices and a local manufacturing facility, the Company is now firmly established in the local market. This has clear benefits. At this time, Marel Stork Poultry Processing is working out of local offices in Beijing and Qingdao. The Beijing office coordinates sales and service not just for poultry customers but for red meat and further processing customers, too. The office in the coastal city of Qingdao, approximately 434 m. / 700 km. South East of Beijing, supports mainly the fish industry. The office team in Beijing has grown substantially this year. Besides expanding the sales team, with sales managers specialized in a particular industry, there is also emphasis on further building the local service team. Investing in employees gives top-class service In the coming months, the existing service team will be further strengthened with engineers and service coordinators. Local employees speaking the local language and knowing the local culture will be able to react better and quicker to questions from customers. A level of service will be provided which customers have come to expect from Marel Stork. Local colleagues undergo regular training from product specialists so that they are always up to date with the latest developments. service contracts available from Marel Stork Poultry Processing are proving themselves in more and more markets. Changing market; more automation Marel Stork Poultry Processing s investments in a local presence are in perfect harmony with the strong growth in demand for chicken products in China. Bone-in products and giblets are enormously popular. Fillet and fillet products are becoming ever more popular too. Poultry production is being scaled up to high speed to be able to satisfy the demand for safe meat. Thanks to the availability of sufficient labor, cut-up and deboning in China is done chiefly by hand. The expectation is that this will change in coming years when manual processing will be replaced by automatic processing at high speed. For this, Stork can offer all possible solutions such as the ACM-NT cut-up line and various breast de-boning solutions such as the AMF-BX or the FHF-XB system for harvesting a variety of breast fillet products either with or without the Sensor X for bone detection. for both the primary and secondary process and for further processing too. For all of these disciplines the Company has various advanced technologies available. We are being asked to do projects for more and more customers where Stork Poultry Processing supplies kill, evisceration, cut-up and de-boning solutions combined with, for example, an automated cutting line for de-boned meat from Marel. This is the right equipment for cutting de-boned thigh meat into products such as thigh steaks, KFC steaks, strips and cubes and for cutting breast fillet into items such as weight controlled products, product cut at 45 and chicken popcorn. The equipment works at very high speed and with a very high degree of accuracy. Within Marel, under the Townsend Further Processing brand, we offer a wide range of further processing products. Some product examples Every project is, of course, different. It is precisely because of our strategy of think global, act local that we know even better how to tune in to the individual circumstances of each local market. In China this mainly means the substantial up-scaling and automation of different parts of the process which now are still mostly done by hand. Food safety, traceability and high capacities are important here. Some examples of our products which fit the bill are the Nuova evisceration machine, modular INNOVA software, cutting lines and the grader programme. Nuova eviscerator INNOVA this production control and information software system, modular and extendable, presents all necessary control data for the whole process, the KPI s for each phase and enables complete traceability from door to door. Complete tracking and tracing is very important indeed for international chains such as KFC and McDonalds. Nuova Nuova is the beating heart of a modern evisceration line and it is here that we have the viscera pack line which either automated or not ensures optimal giblet harvesting. Very high drawing performance, unequalled hygiene and high giblet harvesting yields are what Nuova stands for! Automatic cutting lines these lines are equipped with the I-Cut 36 which cuts de-boned skin-on or skinless chicken meat into strips and with the I-Cut 22, which cuts meat into cubes of the desired shape and weight. Marel is the only company offering solutions, accurate in both cut and weight, for the automatic production of these cuts of de-boned chicken meat, which are so popular in the Far East. Graders Marel graders range from simple weight graders to highly sophisticated grading systems including in-feed and batch takeaway systems. Graders can be custom-made for each customer, so their configurations and sizes are virtually unlimited. Development of local stock and production Besides investing in staff Marel Stork Poultry Processing is also building up its local stock of spare parts so that customers can have quick access to any necessary original quality spare parts. At the same time, a number of fast-moving products are now being made in Stork s factory in Beijing. In this way, we are able to give customers in China even better support. Preventive maintenance Good maintenance using original Stork Poultry Processing spare parts is essential for keeping whole system yields and uptime at the highest levels. For a higher capacity plant, a preventive maintenance contract is always a worthwhile investment. Experience has shown that the total cost of ownership (COO) of the whole installation goes down and uptime up. The (preventive) maintenance Controllable quality The Chinese market is becoming increasingly convinced that automatic processing is good for better and more consistent end product quality, the pursuit of which dovetails with the demands being made by the international food service chains. Examples are KFC, which is enormously popular in China, and McDonalds, of course, for both of whom consistent and, in particular, controllable quality (complete traceability) is essential. Marel s INNOVA software is the perfect tool here. This modular software package offers all the management tools needed and ensures full traceability from grower to end product. All in one company Stork Poultry Processing represents the poultry processing industry within the Marel organization. By coming to Marel, the Chinese customer has come to the right place Local offices in Beijing and Qingdao Current projects At this moment there are many projects on the go in China, of which some examples are: Fengxiang Cofco Henan Dayong Tyson Haimen Boxing Xin sheng Qianhu Nong mu Husi (OSI) Penglai Minhe CP Qingdao Jinluo 2 kill and evisceration lines (10,500 bph), 2 Kakugiri lines and 1 Rotocrumb for the perfect application of crumb coating 2 kill and evisceration lines (12,000 bph), including grading 4 evisceration lines (12,000 bph) and a complete Townsend Further Processing line including RevoPortioner, a coating line and SpiralOven 1 kill and evisceration line (10,500 bph), including grading 2 evisceration lines (12,000 bph) 1 evisceration line (12,000 bph) 1 Townsend Further Processing RevoPortioner and 1 Marel Platino Flattener 1 evisceration line (8,000 bph) and a Marel high speed grader line 1 Marel high speed grader line 1 Marel high speed grader line For more information go to: or contact us on: T +86 (0) or info.china@marel.com A strong local presence with a complete range of high quality products and services attuned to developments in the Chinese market! That is what Marel Stork Poultry Processing stands by. This is the basis on which, together with our valued Chinese customers, we build with confidence for an even more successful future for the poultry industry in China

8 A systematic approach to solving evisceration challenges Speed and quality = money in poultry proces Being a branded company, quality is everything, said Mandy Korpal, Plant Manager, GNP Company, Arcadia, WI. Their decision to install a two complete evisceration line solution from Marel Stork Poultry Processing was based on a number of factors including quality, safety and ergonomics, automation and overall efficiency. Korpal noted that they have achieved every one of their goals with this integrated system. Our team couldn t be happier with our new process. We have improved ergonomically as well as quality recovery. Critically, an evisceration line must perform with high performance, to avoid slow down by USDA inspectors. The Nuova evisceration system, combined with using a 2-piece shackle, has a transfer pack in shackle performance of above 99 percent which is well above the USDA protocol, giving operations both the speed and the quality they need for optimum throughputs and yield. How is a consistent, greater than 99 percent performance achieved? Through the careful thought and design of each piece of equipment, as well as the integration of the individual pieces within a line. Accurate, hygienic, consistent evisceration As one of the world s largest processors and marketers of chicken, Tyson Foods, Inc. carefully considers which vendors to partner with on new projects. When the time came to purchase a new evisceration line, they chose Marel Stork Poultry Processing equipment for three main reasons, according to Keith Riley, Complex Manager Tyson Foods Union City, Stork s history, price and performance guarantee. Continued volatility in the market, including feed and transportation costs as well as consistently high breeder placements, means processors must squeeze every cent out of every broiler that comes to production. Increasing yields and line efficiency without increasing labor is a goal for most processors as is capturing new sources of income, such as from giblets. Using technology to maximize processes With Marel Stork Poultry Processing innovations in technology, there are possibilities not previously even imagined. The advanced controls can tell operators when and where a fault occurs and even maintains a history for management to optimize their process control. Speed Following, a fully programmable feature, maximizes shackle fill rate and, therefore, line efficiency and can reduce staffing needed for the re-hang table. Marel Stork personnel can remote into the system to evaluate processes, provide guidance on problems or even fix them directly without the downtime and costs of bringing in a service technician. Customized aftermarket care Both GNP Company and Tyson chose a maintenance agreement which can be tailored to the individual needs of the company. The equipment is performing wonderfully, said Korpal. However, after-market care was a very important factor in the cost of ownership piece of our decision matrix. A maintenance agreement provides a company with the support that is often needed as their own technicians learn about new equipment and solutions. We had a relatively smooth startup with full support from Marel Stork Poultry Processing, Riley said. Customer service has been superb with excellent communication from our Stork contact. Viscera pack For GNP Company, the whole line solution was the value they were looking for. We had our list of objectives. We rated all objectives against our matrix. We looked at everything including the top goals, but also life expectancy, Cost Of Ownership, future sustainability, ease of management. We used a point system against our weighted objectives, stated Korpal. Looking back at our plan from a year ago we ve achieved exactly what we had planned to do. Tyson has also achieved their goals and is pleased with the operation of their system. According to Riley: If we had the need to install another evisceration system today we would choose Marel Stork Poultry Processing. Being a branded company, quality is everything! Mandy Korpal, Plant Manager GNP Company, Arcadia, WI The Leg Dressing Module Making hip and leg joints pliable for optimum trussing Trussing whole broilers manually requires flexible leg and hip joints. Otherwise it is ergonomically hard work for the operators. Because chilling stiffens the joints, products are frequently trussed before chilling, directly after the evisceration line. The Leg Dressing Module enables you to truss after chilling, without any hard work being involved. The Leg Dressing Module mechanically bends and stretches both leg and hip joints of boilers to make them pliable again. The amount of force needed for trussing is reduced by at least 70%. This fits in well with our strategy of better ergonomics for your operators. Another advantage is that if products are to be trussed after chilling, typical product flow logistics do not have to be compromised. Manually trussing broilers before chilling is not, of course, the best solution. Logistically it means you have to take broilers out of line, truss them, move them elsewhere for chilling and then process them once again. Bacteriologically and from a yield point of view it is best if broilers are first chilled and then trussed and packed. With broilers which have been trussed after chilling there is also less chance of skin discoloration. In this way, the leg dressing module also contributes to improved presentation. Operation The carcass (the whole broiler) enters the carousel machine and is pushed into a folded position by the vertical movement of the unit with the knee and hip joint being bent to the maximum. A spring in the unit applies the right technological force and ensures the right position of the unit for different product sizes within a flock. The unit then moves down and the legs unfold. The whole then leaves the Leg Dressing Module. Settings of the module can easily be adjusted to accommodate different broiler sizes. Option for long legs There is an option available for so called long legs (should you want to leave a larger part of the shank on your product). A cam controlled plate bends long legs during the folding action of the product. Standard for safety and hygiene The Leg Dressing Module RS can be disengaged from the overhead conveyor by lowering the carrousel pneumatically. In disengaged mode, the carousel can be turned manually for cleaning purposes. During this operation technological settings will not be affected, ensuring a perfect start once the module has been re-engaged. To reduce cleaning times, Marel Stork Poultry Processing has optimized the design of the Leg Dressing Module by making its construction more open. To improve hygiene, the frame has sloped horizontal surfaces and has been designed to prevent blind spots. Reference Series The Leg Dressing Module is part of the Reference Series (RS) family. Like all the other RS-modules it has a selfsupporting frame to reduce the amount of overhead steelwork necessary, the so-called beam plan. This simplifies installation. Installation of RS machines has also been simplified by providing most utility connections at a central column. ADVANTAGES OF THE LEG DRESSING MODULE AT A GLANCE... Bends and stretches both leg and hip joints Improved ergonomics. An independent study confirms that using the module minimizes the risk of repetitive strain injury Improved product safety and hygiene Better inline logistics Provides the option of dressing long legs. The unique design of the Nuova system positions the heart and lungs above a pack shackle with the rest of the pack, below. As a result, giblet harvesting, whether manual or fully automated, can be done faster, more simply and in the most hygienic circumstances. Cleaner and more accurate evisceration sets the stage for other processes down the line, aimed at utilizing additional parts, thereby gaining additional income. The team at Tyson has been very pleased with both their installation experience and the operation of the system which has allowed them to meet their objectives for the project. The equipment has met or exceeded the Stork guarantees allowing us to reduce staffing, noted Riley. Cost of ownership for the whole system is low due to less expensive chains, plastic trolleys that prevent corrosion issues, an opener which can use an off the shelf blade to prevent downtime and a simple, open mechanical design that allows for easy cleaning and maintenance without disrupting the processing settings. The leg dressing module is the perfect solution for trussing after chilling and for accosciamento, a presentation popular in Italy. Previously, whole broilers could only be trussed properly unchilled. The leg dressing module now allows you to do this job after chilling too with little force required. Nuova

9 Two new milestones in Spain Sharpened focus on Argentina Marel Stork Poultry Processing is proud to announce two important new milestones in the Spanish poultry processing market. The beginning of 2011 saw the commissioning of the market s first maturation tunnel at Grupo Sada s processing plant in Valencia. In the autumn, Spain s first CAS multi-phase controlled atmosphere stunning system for turkeys was successfully commissioned at Grup Alimentari Guissona. Grupo Sada first maturation chill system for broilers Grupo Sada, a subsidiary of the multinational Dutchbased Nutreco group, is Spain s leading poultry producer. It employs some 3,500 people and has nine poultry processing plants and one further processing plant. Its CUK and Frichet brands are household words throughout Spain. The Company controls all aspects of the process from grandparent stock right through to distribution of the final product to the end consumer. Being able to trace all products from feed to food is central to the Company s philosophy of supplying only products of the highest quality and of being Closer to the Consumer. The prospect of improving yield, quality and product presentation using a technique which would also enhance traceability stimulated Grupo Sada s interest in in-line maturation chilling. The Company therefore decided to install the system at its Valencia plant as a first step towards full in-line maturation. The system will handle up to 9,000 bph of an average live weight of 3kg. / 6.6 lb. Two stage process to chill and tenderize In-line maturation chilling is a two-stage process. During the first stage, forcefully circulated cold air Grup Alimentari Guissona first controlled atmosphere stunning system for turkeys Grup Alimentari Guissona set up its business in Since then, the group has grown into a major force in the Spanish red meat and poultry industry and prides itself on being able to get its large range of products from farm to fork within twenty four hours without having to go through any intermediaries. Not only is all production vertically integrated; distribution and sale of all products through its bonarea chain of outlets is also in the group s hands and under its direct control. Besides cattle, pigs and chicken Grup Alimentari Guissona also raises and processes turkeys, an important component in the group s mix of products. To improve the turkey process, the decision was made to replace electrical stunning with Stork Poultry Processing s CAS-T controlled atmosphere stunning system. Hanging live turkeys is hard work and a stressful experience for workers and birds alike. Wing flapping during shackling and transport to the electrical stunner causes damage and can compromise quality and yield. quickly reduces the temperature of all exterior and interior surfaces to inhibit the growth of bacteria. During the much longer second stage, less cold air is circulated more gently - to chill the birds gradually to the required end temperature while at the same time allowing enzymes to do their tenderizing work. To aid chilling, keep weight loss at a minimum and ensure optimum product presentation, a thin film of water is applied to exterior and interior surfaces at set intervals during both stages of the chilling process. Manual unloading matched to system capacity With the new system, able to handle up to 1,200 male turkeys per hour / 20 per minute or 1,800 females per hour / 30 per minute with live weights ranging from 4.5kg / nearly 10 lbs to 16.5kg / 36 lb, birds are removed manually from their transport container and placed on a belt taking them directly to the system. To ensure birds are supplied at the correct rate, operatives unloading the containers are warned visually if they are working too quickly or too slowly. Any birds dead on arrival are removed immediately after unloading and do not enter the stunning system. Full tracking and tracing Maturing birds in-line also saves labor and considerably improves plant logistics. Birds can be tracked and traced accurately through the process, a feature which, as we have seen, is particularly important for Grupo Sada. Two-stage welfare friendly process The Stork Poultry Processing CAS-T system is a two-phase process designed to stun effectively while subjecting birds to the minimum of discomfort. In the first phase, a humidified atmosphere of oxygen, carbon dioxide and nitrogen gently induces unconsciousness. With birds already unconscious, the longer second phase uses an increased concentration of carbon dioxide to stun them irreversibly. They are then hung to the killing line. Kinder to both man and bird Grup Alimentari Guissona was quick to see the same benefits experienced by other leading European turkey processors using the system. Hanging unconscious birds is a lot easier than hanging live ones and kinder to both man and bird. No wing flapping and no electrical stunning means fewer blood spots and broken bones improving cutting accuracy and reducing the need to trim. Other users of the system have also reported better bleed out and reduced fecal contamination. In short, its investment in Stork Poultry Processing s CAS-T system is already bringing Grup Alimentari Guissona better yield, better quality, labor savings and improved animal welfare. Partnership milestone Controlled atmosphere stunning at Grup Alimentari Guissona and the maturation chilling installation at Grupo Sada s Valencia plant are important milesones in Stork Poultry Processing s ongoing partnership with Spanish processors, a partnership whose aim is to improve production efficiency and provide Spansh consumers with safe, high quality poultry products at the best price. Last year we wrote about Stork Poultry Processing s return to this important South American market. A new agent with many years experience in the poultry industry, new arrangements to provide customers with prompt and effective after sales support and, last but not least, the right equipment at the right time, have resulted in the installation of cutting-edge technology equipment at a number of Argentina s leading poultry processing companies. As part of its strategy of sharpening its focus on the market, Marel Stork Poultry Processing took part in the Congreso Latinoamericano de Avicultura 2011 held at the prestigious La Rural convention centre in Buenos Aires under the banner Latin America an environmentally friendly world food reservoir. Growing number of installations To underline Marel Stork Poultry Processing s growing presence in the market, 2011 was a busy year for the Company s installation crews and the coming months will see them working even harder. Grupo Rasic, based at Ezeiza in Buenos Aires province, is in the process of commissioning an all-new Nuova highspeed evisceration and giblet harvesting system. The new equipment will be able to operate at 12,000 bph. / 200 bpm. and has been designed to handle birds of up to 3.6 kg / 7.9 lb individual live weight. For the first time in its history Grupo Rasic will be harvesting hearts, livers and gizzards fully automatically. Grupo Rasic is one of the two largest poultry producers in the country and has a long tradition in the poultry business. It was founded back in 1958 by the Rasic family, immigrants from today s Croatia, and is now run by brothers Ivo and Milenko Rasic. The Company, which also actively exports, is vertically integrated and is well-known for its Cresta Roja brand. It produces whole birds and a wide variety of cut-up, marinated and cooked product. The new evisceration and giblet harvesting system will fit in perfectly with the Company s focus on supplying its customers with high quality products. Machines for Patagonia Pollolin SA from Cipoletti in Patagonia at the southern tip of Argentina has recently commissioned Stork Poultry Processing s latest RS (Reference Series) venting and opening machines in its existing evisceration line. The new machines handle up to 8,000 bph. / 133 bpm. Pollolin SA was founded by the Maionchi family in 1961 and prides itself on being a family concern for families! The Company is vertically integrated from incubation right through to distribution of the end product. The Company produces whole birds together with a comprehensive range of cut-up poultry cuts, de-boned meat and other products. Pollolin is committed to providing its customers with safe, high quality products and insists on full traceability from the farm to your table. In this context the new venting and opening machines are contributing to the company philosophy by combining accurate high performance with extremely low levels of fecal contamination. Another new greenfield project The Argentinian poultry market is expanding strongly and new production capacity is coming on line all the time. An example of this is a new 6,000 bph. / 100 bpm. greenfield plant to be opened in the middle of this year by Mark SA in Rosario. Mark SA has chosen Marel Stork Poultry Processing as an important partner for the new venture. Stork will be supplying killing, scalding, plucking (picking), automatic evisceration and whole bird grading equipment. The kill line will include the new K15 automatic killer, able to do throat or side of the neck cuts and able to perform extremely accurately at high line speeds. Evisceration will be by Nuova, a machine becoming increasingly familiar to Argentinian processors. Immediately after removal from the carcass, drawn viscera packs will be transferred automatically to a separate processing line where hearts and livers will be harvested manually from the packs hanging in a special shackle. This process can be partly or fully automated in the future. New RS series cropping, neck cracking, final inspection and inside/ outside washing machines will ensure a carcass that is clean inside and out. After chilling, all carcasses will be hung to a Stork Poultry Processing selection line where they will be graded for Grupo Rasic, based at Ezeiza in Buenos Aires province. quality at a QS-3 manual grading station and then weighed in-line for automatic collation into fixed weight packs. Sharpened focus comes at just the right time Grupo Rasic, Pollolin and Mark SA have joined, or soon will join, the growing number of Argentinian processing plants benefiting from the latest Marel Stork Poultry Processing technology. Sophisticated consumers at home and exposure to demanding markets abroad have led processsors to focus increasingly on product quality and hygiene. Rising volumes, longer processing hours and increasing costs have turned automation and production efficiency into key issues. Marel Stork Poultry Processing s sharpened focus on Argentina has come at the right time! 16 17

10 Finishing the job properly Marel weigh price labellers The new Marel Multihead Weigher IQF Poultry With product packed ready for sale, the time has now come to put a price on the good work done. Marel offers a complete range of weigh price labellers, checkweighers and labelling machines and systems, which can be fully integrated into a Stork Poultry Processing production line series weigh price labellers The 9000 series can handle from 40 to 160 packs per minute from 80 x 60 x 6 mm / 3 in x 2 in x.25 in (length, width, height) to 350 x 240 x 150 mm / 14 in x 10 in x 6 in. The equipment will work with both chemi thermal and thermal transfer labels and can apply these to the top, base or side of a pack. It can also handle so-called C labels. These wrap round three sides of a pack allowing information to be printed on its top and side. C labels are popular with retail outlets in some countries as they make it easy for the consumer to identify product stacked on shelves, particularly on higher supermarket shelves. Labelled whole broilers. What you see on the touch screen is what you get on the label. By dragging and dropping, text can be positioned correctly on the label and the position of the label on the pack set. When the time comes for a product or label change, the new label set-up can be checked and preparation made for the new product without having to stop the machine, saving a considerable amount of time. Labels can be configured off-line on a PC and data transferred to the weigh price labeller itself. Systems for chaotic flows Complete weigh price labelling systems consist of a single weigher followed by up to eight labellers, each of which can handle a number of different pack sizes at the same time. Such a system will allow a variety of different packs for different retail customers to be handled on a single line. Different packs can arrive chaotically, in no particular sequence. Using the appropriate automatic equipment (weigher, optics, bar code reader), these will then be identified by weight, height or bar code and assigned to the correct labeller. Whole broilers, boxes and crates too There is a labeller available for irregularly shaped product such as whole chicken as well as a machine capable of applying either top or C labels to retail packs with a minimum of changeover time between the two label types. Boxes and crates have not been forgotten either as well as manual multi-channel box or crate packing stations. After packing, labels can be applied automatically to the top of a box, to its base, front, back or even around its corners. Innova monitoring and control The weigh price labellers can be integrated into Marel s INNOVA plant monitoring and control system. A module of the system allows multiple weigh price labellers and labelling systems to be managed real-time from a central point. This module can then interface with Innova Labelled thigh fillets, skinless and boneless. modules for product distribution (Stork PDS-NT), stock control, order picking and dispatch and for monitoring and controlling yields. Together, these add up to a single integrated plant-wide system giving plant management the information it needs to do its job efficiently. Reliable, easy to live with and friendly on cost of ownership The Marel weigh price labellers are accurate, reliable, easy to live with and inexpensive to own. Consistently high weighing accuracy is the result of more than thirty years experience of dynamic weighing techniques. Detailed attention to printing technology has provided a print head capable of printing up to two million labels depending on individual circumstances. The equipment s modular design, using standardised structures wherever possible, means fewer spare parts in stock and an easier job for maintenance staff. Marel Sales and Service Units around the world are on hand to provide training and technical back-up. Based on many positive user experiences of the Multihead Weigher series, Marel has now developed an entirely new machine exclusively for the poultry industry. Robust, easy to use and designed for optimum throughput with minimum giveaway, the Marel Multihead Weigher IQF Poultry handles poultry products at high capacity and with great accuracy. Known for their reliability, the Marel Multihead Weigher series of machines gained their excellent reputation based on their solid construction, compact design, easy-to-use, multi-lingual user interface, and extremely low giveaway. All this was taken into account when work began on developing the new Marel Multihead Weigher IQF Poultry. As a result, these proven features have been transferred onto the new machine and new ones developed to create the perfect IQF poultry solution. Designed to easily withstand the harsh environment of frozen product handling, even when running 24/7, 365 days a year, the unit s large, new and highly versatile 7-liter / nearly 15 pound hoppers can handle all kinds of batch sizes, and are designed to prevent products sticking to them. A weighing system that includes an overload and anti-shock system helps extend the service life of the unit, as well as reducing downtime and cutting operation costs to a minimum. The AFA (Automatic Frequency Adjustment) adjusts the line vibrators automatically, in order to maintain the highest possible throughput. User friendly touch screen operation 9000 Series weigh price labellers are operated from a user-friendly touch screen at the machine itself. Set-up menus guide the operator through machine and label set-ups. Configuring the system is easy. An additional benefit is that new staff can be trained much more quickly The system can be operated in a number of key languages. Last but not least, the Marel Multihead Weigher IQF Poultry can be dismantled without tools, making it very easy to clean and maintain, and a particularly safe, hygienic solution. To read more about the new member of the Marel Multihead Weigher family, visit multihead High throughput: up to 60 batches per minute, depending on product type and batch size Consistent, maximum-capacity product flow, thanks to Automatic Feeder Adjustment (AFA) technology Extremely low giveaway Easy to operate Very hygienic All-time low maintenance costs More on Marel Multihead Weighers Marel Multihead Weighers will handle all infeed, sorting, mixing and weighing requirements, automatically portioning and packing products into virtually any type of packaging. Weigh price labeller WPL 9100 Products are dispensed into hoppers by vibrating feeders and weighed into exact portions. Food items ideally batched with a Multihead Weigher include IQF fillets, toppings, diced meat, poultry strips, nuggets, wings and drumsticks

11 Let s meet in person We would like to welcome you at one of our trade shows March Ildex Vietnam Ho Chi Minh City Vietnam 1-3 April Agrame Dubai UEA May AVI Africa Johannesburg South Africa 4-6 July Indo Livestock Jakarta Indonesia July Avicola Porcinos Buenos Aires Argentina 5-8 August WPSA Salvador Brazil September Mercoagro Chapeco Brazil September VIV China Beijing China September Saudi Agriculture Riyadh Saudi Arabia October VIV Mexico/Figab Guadalajara Mexico 8-12 October Agroprodmash Moscow Russia 30 Oct - 2 Nov AgroWorld Almaty Kazakhstan 31 Oct - 2 Nov Animal Farming Expo Kiev Ukraine November Eurotier Hannover Germany November Dawajine Casablanca Morocco Global presence Marel Stork Poultry Processing is the leading worldwide supplier of processing systems for broilers, turkeys and ducks. With a strong focus on innovative technologies and service, we provide inline solutions for every processing stage and capacity level. We offer integrated solutions spanning single processes to complete processing plants, including live bird supply, slaughtering, scalding and evisceration, chilling, cut-up and deboning, X-ray bone detection, portioning and slicing, weighing, grading and batching, packing, production control software and preventive maintenance programs. Our products enable our customers to produce a vast range of products while maximizing yields, product quality and value, as well as providing full traceability. Marel Stork Poultry Processing B.V. P.O. Box AC Boxmeer The Netherlands T: +31 (0) F: +31 (0) E: info.poultry@marel.com Marel Stork Poultry Processing Inc. P.O. Box 1258 Gainesville GA USA T: (+1) F: (+1) E: usa.poultry@marel.com Stork Poultry Processing is a trade name of Marel Stork Poultry Processing B.V. Copyright Marel Stork Poultry Processing B.V., The Netherlands, 2010: All rights are reserved. Any reproduction or modification of all or part of this publication, regardless of the method of reproduction or modification used and regardless of the carrier used, is strictly prohibited, unless written authorization by Marel Stork Poultry Processing B.V. has been obtained beforehand. Those acting in breach of this notice expose themselves to criminal and civil prosecution, in accordance with the international conventions and copyright laws. The data published herein answer to most recent information at the moment of publishing and are subject to future modifications. Stork Poultry Processing reserves the right to modify the construction and the execution of their products at any time without any obligation on their part to modify any equipment delivered before accordingly. The data mentioned are meant as an indication only. Stork Poultry Processing assumes no responsibility for errors or omissions in the data published or use of the data published. The publication of these data may not be interpreted as a warranty or guarantee of any kind (either express or implied). INSIGHT-SPP-Mar12-ENG V O L U M E 1