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Exploiting the Full Potential of Automation in Hungary

Business growth sometimes requires a new approach or an optimized one. In Hungary, BAADER supports Mecsek Baromfi Kft in automating its processing for increased capacity.

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

The Hungarian poultry meat producer, Mecsek Baromfi Kft, part of Y Group, has slowly developed its business vertically since 1991. Now, it grows its chickens, own proper feed mills and processes poultry products. As the business has developed, the need for increased capacity and automated processing has risen.

Teamwork from Planning to Installation

Mecsek Baromfi Kft processed the meat on a small slaughtering facility in Mágocs for twenty years. However, a relocation became necessary due to the limited capacity and location of the existing plant. Mecsek Baromfi Kft decided to construct a new, automated plant for increased capacities.  

BAADER worked with the processor to analyse and optimize each processing step, intending to meet current and future requirements for a modern poultry processing plant that can run 3000 birds per hour.  

"We are grateful for the advice from BAADER during the planning phase. While we were planning the new processing plant, we visited four modern BAADER sites outside Hungary and those visits inspired and convinced us to go for a BAADER solution", says Mr Lajos Horvath, founder of Mecsek Baromfi Kft.  

The outbreak of the COVID pandemic caused travel restrictions across Europe in 2020, challenging installations of the new equipment. Nevertheless, those obstacles were short-lived.  Project planning, unrestricted teamwork, a strong presence in Hungary, and good communication helped Mecsek Baromfi Kft and the BAADER team in executing the project successfully.  

The project comprised BAADER solutions such as live bird handling, electrical stunning, scalding, picking, evisceration, chilling, cut-up, and breast deboning. The processing is kept in line and with a high degree of automation.  

Installation of the automatic Breast Deboner 656

Automation Allows for Higher Capacities

Increased capacity and desire to reduce labour dependence instigated the automation of production at Mecsek Baromfi Kft. Consequently, the automation provided other benefits such as consistent processing and more hygiene and food safety. Automatic processing lines are independent of the performance of individual workers. Therefore, they have a more predictable outcome all year round.  

Moreover, manual handling can contaminate poultry meat. By keeping the process in line and automated, Mecsek Baromfi Kft. has considerably reduced the risk of bacterial contamination.  

Conveying Crates to the Point of Shackling

At the new reception system, roller conveyors transport full crates to automatic de-stacking, while the old plant was characterized by manual handling of crates. The new reality saves workers from backbreaking work. There is now reduced bird stress in the reception area due to smooth movements in de-stacking and conveying. Also, the automatic crate transport provides constant feeding birds to the shackles, thereby optimizing line utilization.  

In three steps, an automated crate washer cleans empty crates to prevent cross-contamination at the farms.

A line of installed ProFlex shackles  

Getting a Clean A-Grade Bird

Automating the evisceration process becomes inevitable once a processor increases the processing capacity. At that point, manual evisceration becomes laborious and costly. With this view, Mecsek Baromfi Kft installed an automated evisceration line at the new processing plant.  

During processing, machine adjustment features help Mecsek Baromfi Kft to control bird positioning to prevent damaged carcasses or giblets and reduce cross-contamination by faecal material (e.g. Campylobacter contamination).  

The Eviscerator 210 effectively withdraws the viscera package and prepares it for inspection and further giblet harvesting. Simultaneously, thorough bird washing at the end of the evisceration line reduces contamination and prepares the eviscerated bird for consumption.  

The automatic evisceration line at Mecsek Baromfi

Keeping the Product in Line

Mecsek Baromfi Kft made another important decision when planning the new slaughterhouse. That decision was stopping the chilling of birds on racks — the ‘Christmas Tree’ solution. Instead, they adopted automatic transfer, from evisceration to air chilling. The possibility of cross-contamination has been reduced because the birds stay in their shackles from slaughter to cut-up.

Databased Determination of Bird Use

The Transfer Machine from chilling to distribution uses a patented static weighing principle to capture the accurate weight of each bird, while a sophisticated vision camera on the distribution line records the quality grade of the birds automatically.  

The BAADER production management software uses both weight and quality grade to determine the best-fit production for each bird. Thus, ensuring that Mecsek Baromfi Kft meets daily sales orders.  

Adding Value

The cut-up and breast deboning which was done manually are now automated and in-line. The modular ProFlex cut-up system has bypass functions that allow the processor to produce the wing, leg and breast cuttings for daily production.  

Mecsek Baromfi Kft has installed three wing-cutting modules on the cut-up system: Wing Tip Cutter, Mid Wing Cutter and Whole Wing Cutter. When bypassing specific wing cutting units, the processor obtains flexibility to process different wing products: whole wing, drummette, middle wing (mid joint), middle wing with tip and wingtip. Now, Mecsek Baromfi Kft has the flexibility to process the wing products its customers want. Furthermore, the segmented wings provide a greater profit than whole wings.  

BAADER Wing Cutter in use

Meeting the Demand for Boneless Meat

It takes many skilled workers to debone 50 front halves per minute, and the skilled job is crucial to yield, quality and profits. With the new processing plant, Mecsek Baromfi Kft has opted for automatic deboning on the popular BAADER Breast Deboner 656. BAADER has been developing breast-deboning machines for the poultry industry since the 1980s. The Breast Deboner 656 consolidates this experience. It is a stable machine that protects yield by measuring front halves individually and adjusting the cutting tools accordingly.  

BAADER Breast Deboner 656 slicing through a meat piece

Prepared for the Future

The solution design has already considered the possibility of a future capacity increase – up to 6000 birds per hour. The new greenfield plant prepares Mecsek Baromfi Kft for the future to exploit the full potential of automation.  

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

Go to case

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

Learn more

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Exploiting the Full Potential of Automation in Hungary

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