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.
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.
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.
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
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
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
E-Mail: ba-mx@baader.com
Tel.+52 55 7924 4146
Each year, more than 100 billion tons of chicken meat are produced worldwide. As poultry production continues to grow, also the number of poultry by-products and waste grows. With the increasing demand for protein worldwide, waste management and the efficient utilization of meat by-products become more important. Efficient utilization of poultry processing by-products can potentially increase revenues and decrease costs for disposal of waste. The challenge is to recover valuable by-products in a cost-efficient way or convert waste into valuable by-products. Four ways how you can add value to your supposed poultry leftovers:
More than four million tons of blood are collected from poultry slaughterhouses each year. A small amount of it is used to make e.g. blood sausages, blood curd, or bread for human consumption. The majority is going into feed supplements in livestock feed due to their high nutritional value. However, there is one part of the blood that contains high potential functional ingredients: blood plasma. It can be separated easily from the red blood cells by precipitation methods or via centrifugal forces. The functional components in blood plasma can change and control food textures. Blood plasma proteins have excellent emulsifying capacities, foaming properties, and gelling properties which can be used in the food industry as natural functional ingredients. Besides that, bioactive compounds in blood plasma can be isolated and capitalized for medical uses in the pharmaceutical industry, like in culture media, biological assays, or as stabilizers in vaccines. Purified blood or blood components can also be used to help replenish blood or fluid loss in animals.
Obviously, feathers are plenty in the poultry processing industry – a high potential co-product, as they consist of up to 90 per cent protein. The challenge with these keratin-rich feathers is that they are indigestible to humans and animals due to their strong stabilizing protein bonds and have low value as such. Processing feathers in the right way, can turn them into a new, more valuable co-product. Enzymes from microbiological origin or steam pressure cooking can help to degrade feathers into more valuable feather digests. Feather digests can be used to improve animal feed formulations and as fertilizers for agricultural purposes. On top of that, specific protein fractions can be isolated from the feather digests because of their anti-hypertensive, antimicrobial, and antioxidant activities.
Animal organs and glands offer a wide variety of flavours and textures, and often have a high nutritional value. Especially livers, hearts, and gizzards are used for human consumption. In various European as well as Asian countries, also some other parts are treasured as a delicacy, like the intestines, the crop, and the pre-gizzard. Organs not used for human consumption, mainly end up in pet food or animal feed. Some organs have the potential to be further capitalized in the pharmaceutical industry. Animal glands for example are exploited for their hormones, enzymes, and other functional ingredients. Poultry gallbladders have traditionally been used in the pharmaceutical industry in countries including China, India, and Japan. Bile contains interesting components such as bile salts, colour pigments, proteins, and cholesterol. Bovine and porcine bile has often been used for treating digestion problems, bile tract disorders, and constipation. Bile salts supplements have further been promoted for their health benefits. The challenge with poultry glands is their size – this makes it difficult to harvest in a cost-efficient way. However, the potential of making full use of them is huge though.
Cut-up and deboning will leave you with miss-cuts, trimming rests, and other products not selected as an end-product sale. Further processing of supposed leftovers offers high-quality minced poultry meat. With its Refiner series, BAADER offers a technology that has set new standards in the processing industry. It ensures the quality of raw materials in a gentle manner and maintains the natural fiber structure of the meat for further processing. It thus allows processors to gain added value while contributing to a sustainable future. Using minced poultry meat, one must comply with the international and local requirements for fresh meat – they might further be restrictions as to which part of the animal is allowed to be processed. Not just meat, but also bones and cartilage (rests) can be further processed. Co-products such as bone and cartilage contain a considerable amount of the protein collagen. They can be degraded by hydrolysis leading to the formation of gelatin. Gelatin can be used in the food industry for its functional properties, the pharmaceutical industry in capsules as well as cosmetic products.
If you have questions about the best production parameters for protecting the epidermis, reach out to the BAADER experts
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Co-product Handling: Making the Most of What You Have
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