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The Critical Factors Impacting Automatic Breast Deboning

Traditionally, breast filleting has been carried out manually on labour-intensive cone lines, a practice that persists to this day. However, there is a growing trend toward automating this process, and it’s not without reason. Firstly, manual filleting relies heavily on skilled workers who must ensure both high yield and quality. Unfortunately, even with skilled workers, human factors can introduce inconsistencies throughout the working day. Fatigue and lapses in concentration are unavoidable. Moreover, as production line speeds increase, manual cone lines occupy considerable space. As a result, the global poultry industry has witnessed a significant surge in the adoption of automatic deboning lines, encompassing both semi-automatic and fully automatic systems. However, when going from manual to automatic deboning, several factors must be considered.

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.

Committed
Leadership of
BAADER Mexico

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
E-Mail: ba-mx@baader.com
Tel.+52 55 7924 4146

Traditionally, breast filleting has been carried out manually on labour-intensive cone lines, a practice that persists to this day. However, there is a growing trend toward automating this process, and it’s not without reason. Firstly, manual filleting relies heavily on skilled workers who must ensure both high yield and quality. Unfortunately, even with skilled workers, human factors can introduce inconsistencies throughout the working day. Fatigue and lapses in concentration are unavoidable. Moreover, as production line speeds increase, manual cone lines occupy considerable space. As a result, the global poultry industry has witnessed a significant surge in the adoption of automatic deboning lines, encompassing both semi-automatic and fully automatic systems. However, when going from manual to automatic deboning, several factors must be considered.

Comparing Manual and Automatic Deboning Processes

In the realm of manual deboning, skilled workers possess the ability to adapt the process to suit the unique characteristics of each breast cap, allowing them to meet specific quality standards and address certain market requirements. However, when it comes to automation, the adjustment to each individual product is achieved through the use of measuring tools, thereby reducing the need for highly skilled workers to do only the machine setup and maintenance tasks. Furthermore, the incorporation of pre-installed machine recipes further simplifies the operation.

Manual deboning is a labour-intensive process, which heightens the processing plant’s reliance on human workers and amplifies associated costs. Additionally, the human factor introduces uncertainty regarding reliability, such as ensuring consistent worker attendance and achieving predictable production outcomes. Sustaining a team of skilled workers typically necessitates ongoing training efforts, whereas automatic solutions merely require basic tasks like loading products onto the machine. However, it is worth noting that humans possess the adaptability to handle a wide range of incoming products, whereas machines may struggle to optimize their performance if the products fall outside their predefined scope. Moreover, to maintain a certain level of production flexibility, automatic deboning machines must be capable of processing various types of products.

One of the most notable distinctions between automatic and manual deboning lies in the required footprint, particularly when operating at high speeds. Manual deboning, due to the high number of workers involved, necessitates a substantial amount of workspace to comfortably accommodate the task. Conversely, automated tools require minimal space and can operate at higher speeds.

The Importance of the Maturation Process

The maturation process plays a crucial role in transforming the muscular tissue of meat after the animal has been sacrificed. As the demand for boneless breast meat and further processing continues to grow, processors are seeking shorter aging periods. However, striking the right balance in maturation time is essential to achieve the desired deboning quality and yield.

Reducing the maturation time strengthens the intermuscular tissue, allowing for the extraction of visually appealing fillets that remain intact with minimal residual meat on the carcass. However, this approach increases the risk of bone content. On the other hand, longer maturation periods often result in damage to the tissue structure during pulling and scraping, leaving streaks of meat on the carcass. Nevertheless, fillets that undergo an extended maturation process typically exhibit no presence of bones.

Thus, the maturation time of the incoming product significantly impacts the deboning yield and fillet quality. While a lower degree of maturation may initially seem to offer a higher yield with less residual meat on the carcass, it necessitates trimming to address increased bone content. Trimming requires additional workers and inevitably leads to the removal of extra meat around the bone. In contrast, matured incoming products may leave more residual meat on the carcass, but they require minimal or no trimming. Skillfully managing the maturation process is crucial in finding the "sweet spot" that achieves the optimal balance between yield and quality.

Other Factors Influencing the Deboning Process

When implementing an automated deboning process, several requirements must be met for the incoming product. Foremost, the breast product loaded onto the machine should be in good condition. This entails anatomically cutting the wing knuckle to enable the deboning machine to perform the cutting and scraping operations accurately. Additionally, proper cutting of the breast product on the cut-up system is crucial to ensure a suitable fit onto the loading saddle.

Numerous farming-related factors, including aspects like growth conditions, nutrition, and genetic anomalies, exert a substantial influence on the deboning procedure. Weak bones or muscular abnormalities, like spaghetti meat, pose challenges for many processors.  Moreover, the selection of the chilling method also plays a pivotal role in affecting the deboning process. For example, water chilled products carry a heightened risk of skin tearing during the skinning process. Conversely, they do offer the advantage of easier skin removal.

The human factor still plays a role in the automatic deboning process. It is essential to load the incoming products correctly and consistently to ensure the machinery's correct and full utilization. Inline processing tends to be gentler on the incoming product, while matured products brought in bulk can be more susceptible to damage due to the product handling involved. Naturally, maintaining product quality throughout the entire process, right up to the deboning machine, is crucial.

The New Breast Cap Deboner 660A

To meet the increasing demand for deboned breast meat, BAADER added the automatic Breast Cap Deboner 660A to the deboning portfolio. This advanced deboning machine emulates the precision of human deboning by utilizing a measuring tool to determine the dimensions of each breast cap and automatically adjusting the scraping and cutting tools in real time. The result is exceptional performance, delivering high yield and top-quality fillets.

The Breast Cap Deboner 660A offers remarkable flexibility, accommodating a wide weight range for incoming breast caps, ranging from 380 to 1200 grams (+/- 200g within the same machine set-up). Moreover, this deboner can produce a variety of fillet products, including those with or without skin, as well as clean and intact yagen products.

By minimizing the need for manual labour, the Breast Cap Deboner 660A significantly reduces labour costs and eliminates human uncertainty. Only two manual workers are required to load the breast caps onto the machine saddles. This reduction in deboning staff also has a positive impact on the overall deboning footprint. Occupying less than 9 meters, this compact machine easily fits into existing facilities and can even free up space when transitioning from manual to automatic deboning.

Breast Cap Deboner 660A

2 workers, 8.4 metres

Manual dual-lane deboning line

28 workers, 21.3 metres

To enhance control and monitoring, the Breast Cap Deboner 660A incorporates a Human Machine Interface (HMI) control panel located on the plant floor. This user-friendly interface empowers operators to efficiently monitor and adjust deboning process parameters, ensuring optimal performance and yield. With intuitive navigation and pre-set recipes available on the screen, production setup becomes fast and simple, especially during production shifts.

The new Breast Cap Deboner 660A provides an excellent alternative to labor-intensive manual deboning, without compromising on quality, yield, or flexibility. It streamlines operations, maximizes productivity, and meets the evolving demands of the poultry industry.

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

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The Critical Factors Impacting Automatic Breast Deboning

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