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Challenges Processing Big Birds

In recent decades, there has been a significant increase in the size and weight of broilers to improve overall processing efficiency. This translates into the ability to produce more chicken meat per hour, particularly when dealing with larger animals. However, these advancements come with their own set of processing challenges directly related to the accelerated growth rate.

From Farm to Processing 

Once the demand for processed poultry products is identified in the local or regional markets, a farmer may decide to expand into processing. The transition from farming to processing is extensive and  requires careful planning and execution.

To begin, it is crucial to understand the preferences and buying behaviour of potential customers,  whether they are retailers, restaurants, or end consumers. This market insight will guide the development of products that meet customer needs and drive sales.

Joining national or regional industry associations is an essential step. These organizations provide  valuable resources, including access to industry reports, regulatory updates, and networking opportunities. Attending networking events hosted by these associations can also facilitate connections with  industry experts and potential business partners.

BAADER is a specialist in advising on the processing process. With our long-standing commitment  to the poultry industry, we are a qualified partner, offering comprehensive processing solutions that  cater to the specific needs of your operation. Our expertise ensures that your transition from farm to  processing is smooth, efficient, and compliant with industry standards. 

Compact Stand-Alone Processing Plant

The BAADER portfolio is extensive and designed to meet demand regardless of local requirements, processing  speed, or automation level. We are committed to upholding the best processing practices for live bird handling,  hygiene, and product quality, no matter the scale of your operation.

When considering the initial investment in a processing plant, it is crucial to choose a solution that fits your current  needs while allowing for future expansion. An excellent way to start processing is by installing the BAADER Com pact Plant. This ‘plug and process’ solution is easy to install and includes features such as stunning that adheres to  the highest animal welfare standards, effective scalding and plucking, and comfortable manual evisceration. The  BAADER Compact Plant can handle 600 to 1600 broilers per hour, depending on chicken size.

The system offers a high degree of flexibility with adjustable bleeding time, scalding time, and line speed, ensuring  that your processing can adapt to various requirements.

The Compact Plant benefits from the same quality components as our conventional high-speed processing  solutions and is covered by the same comprehensive spare parts service. Conveyorized, in-line processing provides  significant labour savings, increases efficiency, and enhances food safety. Additionally, the manual evisceration  process is more manageable on an overhead conveyor, improving workers’ welfare and ergonomics.

With the BAADER Compact Plant, you get a robust and flexible solution that meets the highest standards of quality  and efficiency, paving the way for a successful entry into poultry processing. 

Customized Solutions for Higher Line Speeds

Higher line speeds require customized solutions to best fit your production requirements. The extensive BAADER  portfolio is designed to meet these demands, allowing for the creation of tailored solutions that perfectly fit your  specific needs. Our modular design enables continuous business growth, providing the flexibility to scale your  operations whenever required.

When working with BAADER, you can be confident in receiving advice based on a thorough analysis of your farm  characteristics, transportation facilities, and production requirements. Whether you are starting your very first  processing plant or expanding your production, we provide comprehensive guidance on all aspects of poultry processing. This includes live bird handling systems, bleeding, scalding and picking times, and the appropriate levels  of automation.

Our expert team ensures that every solution is tailored to meet your specific needs, optimizing efficiency and  product quality. With BAADER, you have a trusted partner dedicated to supporting your growth and success in the  poultry processing industry. 

Careful Handling of Live Chickens 

Transporting birds from the safe farming environment to  the processing plant is a challenging task that impacts  animal welfare, meat quality, and ultimately, plant profit ability. At BAADER, we understand these challenges and  offer a range of live bird handling systems with varying  degrees of automation. Our solutions cover every stage  of the process, including the catching process, lairage  and reception area, destacking and stacking, and wash ing and disinfection. This design flexibility allows you to  choose the system that best fits your operational needs  and ensures optimal animal welfare and product quality

Learn more about our crate and drawer systems

Modular Slaughtering Lines for Future Growth

Modularity is the key to designing a slaughtering line that delivers the highest quality chicken both now and in the future. At BAADER, we prioritize this modular approach when planning and designing slaughterhouses in collaboration with our customers. By understanding your current needs and future plans, we create solutions that not only address immediate requirements but also facilitate easy expansion.

This forward-thinking strategy ensures that your slaughtering line remains adaptable and scalable, allowing you to maintain superior product quality and operational efficiency as your business grows.

Evisceration Solutions for Every Need

Evisceration is the critical process of opening the slaughtered bird and removing the viscera (internal organs and  intestines). This can be done manually, semi-automatically, or fully automatically, and BAADER offers solutions  for all these methods. From manual hand tools to simple semi-automatic devices to fully automated evisceration,  cleaning, and washing lines, we provide the options to match your specific needs.

Manual processing requires a large number of workers on the line, while automatic evisceration represents the pinnacle of modern poultry processing, operating with minimal labour. The decision to choose manual or automated  processes depends on factors such as line speed and access to skilled labour. BAADER’s comprehensive range of  evisceration solutions ensures that you can select the most efficient and cost-effective method for your operation,  whether you are just starting out or looking to upgrade your processing capabilities. 

Learn more about our automatic evisceration solutions

Effective Chilling to Optimize Shelf-Life

After meticulously processing each bird to ensure maximum quality and value, it is crucial to effectively minimize bacterial growth and extend product shelf-life. Achieving these objectives is essential for poultry pro cessors to deliver high-quality and safe food.

BAADER provides a range of chilling solutions, utilizing either water or air as the cooling element. These solu tions are designed to efficiently lower the core tempera ture of each bird to the desired level.

Both water and air chilling methods have their unique advantages and challenges. Water chilling is quick and increases yield but requires careful management to avoid cross-contamination and ensure optimal shelf-life. Inline air chilling is slower but enhances product tender ness and minimizes contamination risks, with controlled weight management through moisturizing. Each proces sor must choose the most suitable method to meet their specific market needs and quality standards.

Learn more about our chilling solutions

Flexibility to Produce a Variety of Products

Whether a processor aims to produce whole chickens or enhance the product’s value through portioning, skinning,  or deboning, BAADER offers tailored solutions to meet these needs. BAADER provides an array of equipment for  weighing, cutting, grading, and packing, enabling even small-scale processors to efficiently meet the demands of  their local markets. Our tailored solutions and modular approach ensure that your processing plant can adapt and  expand seamlessly, supporting your business as it grows and evolves. 

Expert Guidance for Your Poultry Processing Needs

Whether you are considering starting a poultry processing plant or looking to increase your capacity, we offer valuable advice on all process steps. Please feel free to reach out to us using the contact form. Our local experts will get back to you as soon as possible.

Expanding Activities in Latin America

On January 26th, 2024, BAADER opened an office in Querétaro, Mexico, demonstrating our dedication to providing complete poultry processing solutions to customers in Mexico and beyond. Having a local presence improves communication and fosters stronger relationships with our Latin American customers.

Our journey across Latin America began decades ago, and our commitment to the region has only deepened with time. The expansion in Mexico underscores the increasing demand for efficient processing solutions and the necessity for enhanced sales support and service.

The trust and loyalty that poultry processors have consistently placed in BAADER solutions form the bedrock upon which we continue to build our business. As we embark on this new chapter of growth, we remain steadfast in our dedication to delivering excellence.

Leadership of

Meet Victor Garcia, Managing Director of BAADER Food Systems Mexico. With extensive experience in poultry processing, Victor understands market dynamics and local processing needs. His expertise helps him provide optimal layout suggestions, improve line efficiency, and integrate new technologies. Victor’s dedication ensures customers receive solutions that will enhance their operations.

I am thrilled to bring BAADER’s expertise and innovation directly to this vibrant community. Our mission here is clear: to deliver unparalleled service and total solutions. With a dedicated team and a commitment to excellence, we look forward to forging lasting partnerships and making a meaningful impact in the market and the community we serve.
Victor Garcia, Managing Director of BAADER Food Systems Mexico

Meet Victor and His Team at Figap 2024

To further facilitate close contact with our partners, we will participate in the FIGAP show from October 16 to 18. We invite you to visit the BAADER booth, number 1142, to discuss innovative solutions for the Mexican poultry processing industry.

Delivering Prompt
Local Support

From our Mexican office, we offer prompt local service support with a deep understanding of both local production practices and BAADER machinery. The service team is equipped to swiftly address any issues that may arise, ensuring minimal downtime for our customers. At the same time, our global experts stand ready to support our local BAADER team whenever necessary.

Stocked Warehouse

The new office in Querétaro features a stocked warehouse of essential spare parts, strategically positioned to ensure quickt response times and safeguard our customers’ uptime. The strategic location of the office facilitates efficient logistics and seamless support.

Showroom With Our Latest Technological Innovations

Furthermore, we have established a showroom at our premises in Querétaro, designed to showcase our latest technological innovations. This showroom serves as a dynamic space where customers and partners can experience firsthand the capabilities of our equipment and software solutions.

Presentations and Live Demonstrations

Visitors can explore the functionality, efficiency, and versatility of our products through presentations and live demonstrations, gaining valuable insights. This space is intended for showcasing new product launches and market-relevant solutions

Reach Out to Our Mexico office

For any questions or requirements, feel free to reach out to our newly established Mexico office. They are ready to assist with expert processing guidance.

BAADER Food Systems Mexico
P.º Centenario del Ejército Mexicano
Cond. E, Nave E1-095, Pq. Ind. Terra Park Centenario
76269 Querétaro, México
Tel.+52 55 7924 4146

In recent decades, there has been a significant increase in the size and weight of broilers to improve overall processing efficiency. This translates into the ability to produce more chicken meat per hour, particularly when dealing with larger animals. However, these advancements come with their own set of processing challenges directly related to the accelerated growth rate.

The larger size of broilers can be the outcome of both rapid growth and an extended growth period. Consequently, poultry processors are faced with the task of managing not only heavier birds but sometimes also older ones. This dual challenge necessitates specialized handling and processing techniques to ensure optimal outcomes in terms of quality and yield.

Handling Large Live Chickens

One of the initial challenges is effectively managing the handling of large live birds, both on the farm and in the plant reception area. This task is physically demanding. Ensuring a smooth process for catching chickens on the farm is paramount. To achieve this, it is essential to position transport equipment near the catchers to minimize the need for manual carrying. Additionally, the use of transport drawers with spacious openings is crucial to simplify loading while safeguarding the birds from potential injuries as they enter the drawers.

Shackling large birds is already a demanding task, and it becomes even more challenging if the birds are actively flapping their wings. The introduction of Controlled Atmosphere Stunning (CAS) serves the purpose of rendering the bird unconscious before shackling. This allows the shackler to perform their duties comfortably and efficiently, without the bird's movements causing additional difficulties. Furthermore, shackling an unconscious animal causes less distress to the bird. You can read more about CAS here.

BAADER offers two different CAS solutions – above and below ground.

Flexible Processing Equipment

Another significant challenge when dealing with big birds involves the need to modify processing equipment to accommodate these larger sizes. It is imperative that shackles and machinery are purposefully designed to handle the increased weight and size of these birds.

Machines tailored to manage the weight spectrum of bigger birds can greatly enhance both the quality and yield of the meat produced. It is crucial that these machines incorporate multiple adjustment features to adapt the processing to the specific size of the flock, ensuring flexibility in accommodating various bird sizes. Additionally, transitioning from one flock size to another should be seamless, and the equipment should be adaptable to accommodate weight variations within the same setup.

All BAADER evisceration equipment is easily adjustable to fit the flock size being processed.

Adherent Feathers

When dealing with larger bird sizes resulting from an extended growth period, the defeathering can become more intricate. This complexity arises from the fact that the muscles surrounding the follicles are more developed and firmly grip onto the feathers. Additionally, older broilers tend to possess a higher feather count, adding to the challenge of the defeathering process.

In such situations, the scalding process becomes crucial, as it requires complete and fast immersion of the broiler in hot water. The water must swiftly penetrate the dense feather layer, reaching the skin and follicles to effectively loosen each feather before proceeding to the picking phase.

Click here and discover the advantages of the efficient turbo scalding technique, which can significantly simplify the feather removal process, even for challenging-to-pluck birds.

The Turbo Scalder applies a powerful downward water current ensuring an immediate immersion into the hot water and a highly effective heat transfer to the follicles.

Challenges in Meat Texture

For the last ten years, rapid growth rates have been seen leading to unappealing meat structures such as ‘wooden breasts’ causing expensive downgrades. However, processors can prepare the affected meat for further processed products, e.g., nuggets, sausages, cold cuts, etc. Mixing afflicted breast meat with ‘normal’ meat in minced/emulsified products can be a profitable alternative use for meat affected by growth-related myopathies.

BAADERING is an internationally recognized process of separating soft and solid components while maintaining quality. Soft particles are separated from hard ones by using a squeezing belt and a perforated drum. The BAADERING technology can help prepare meat for further processed products and maximize the profit of meat affected by textural defects.

With the gentle BAADERING technology, various poultry materials can be turned into separate products, while preserving the muscle fibre structure to get the highest quality meat.

Cut-Up Systems for a Variety of Bird Sizes

Despite their rapid growth, bones in these broilers may still be relatively delicate. This means that cut-up and deboning must be done carefully to avoid bone fragments in the final product. Selecting an appropriate cut-up system for big broilers poses several challenges for poultry processors as the equipment must be specially designed to handle big sizes and may need to handle various bird sizes within the same processing line. The equipment's adaptability to different broiler sizes is essential for versatility in production.

The BAADER wing cutters are designed to cut one wing after the other – not at the same time. This allows for a higher degree of size variations. Read more here.

Our Wing Tip Cutter and Mid Wing Cutter position and cut each wing separately to optimize the cutting performance and obtain an A-grade anatomical cut.

Deboning Fast-Growing Broilers

Deboning fast-growing broilers presents unique challenges due to their dense muscle development. One effective strategy to address the challenges of deboning fast-growing broilers is to extend the deboning time. This extended period allows for a crucial maturation process to take place, significantly improving the texture of breast fillets.

The maturation process is essential in transforming the muscular tissue of meat after the bird has been sacrificed. During this time, enzymatic and biochemical reactions occur, which contribute to tenderizing and enhancing the sensory experience when eating the meat. For fast-growing broilers, this maturation step becomes even more critical.

Achieving the right balance in maturation time is key to achieving the desired deboning quality and yield. Too short a maturation period may result in tougher meat that is challenging to debone effectively. Conversely, overly extended maturation may lead to meat that is too tender, which can also impact the deboning process negatively by leaving meat on the carcass.

Therefore, finding the optimal maturation time is a delicate task that requires a thorough understanding of the specific characteristics of the broilers being processed. It involves striking a balance between maintaining efficiency in production and ensuring the highest quality of meat. By carefully managing the deboning time and considering the unique attributes of fast-growing broilers, poultry processors can meet the challenges of deboning while delivering meat products that meet consumer expectations for taste and texture.

Discover how the Breast Cap Deboner 660A boosted production for Polish poultry processor Smolarek.

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Gain a deeper understanding of the critical factors shaping automation in breast deboning.

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Challenges Processing Big Birds

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