AVISID‘s New Processing Plant:
A Blueprint for Quality and Future Growth

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Boosting Efficiency: Automation Enhances Line Speeds

A cornerstone of AVISID’s expansion is the meticulously designed crate reception area, tailored to handle increasing line capacities in progressive stages. The initial phase is at the forefront of this expansion strategy, primed to allow AVISID to feed the new BAADER slaughter line with 10,000 birds per hour while designed for easy expansion.

To combat the high temperatures prevalent for much of the year, a cooling system in the lairage area helps protect birds from heat stress. This lairage is designed to support several hours of production, distributed across two future slaughter lines.

Automation plays a critical role in this new facility, particularly in crate handling. Systems for automatic destacking and restacking of crates, alongside a comprehensive crate washing system, streamline operations and uphold stringent hygiene standards. This automation not only enhances efficiency but also minimizes the risk of cross-contamination between flocks.

High-speed processing demands robust, carefully engineered equipment. The BAADER Crate Handling System and processing lines are designed for wear resistance, daily operation, and washdown. The durable construction of the belt and chain conveyors ensures reliable daily production and minimizes ownership costs.

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Precision Processing Ensures Top-Quality Food Products

Maintaining high product quality is crucial, especially given AVISID’s focus on the stringent food service market. Javier Anhalzer underscores their commitment to delivering high-quality products daily. To this end, AVISID has implemented Turbo Scalding, a unique scalding process that ensures effective and uniform heat transfer to the feather follicles to facilitate the subsequent picking process. This Turbo Scalding process minimizes product damage, optimizes quality, and reduces yield loss.

At the core of the evisceration line is the well-proven Eviscerator 218, ensuring the effective and hygienic removal of the complete giblet pack, crucial for maintaining high standards of food safety and quality. The Eviscerator 218 stands out for its precision and reliability. It expertly extracts the giblet pack, minimizing the risk of contamination and ensuring that the product meets stringent industry standards. After the removal process, the giblet pack is seamlessly transferred to a separate giblet line, a key step in optimizing the production workflow. By maintaining a dedicated line for giblets, AVISID ensures that each product is processed under the best possible conditions, resulting in superior quality livers and gizzards that meet consumer expectations.

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Accurate Whole Bird Weighing Allows for Best-Fit Production

Once eviscerated and cleaned, the whole bird is weighed on a TrueWeigher. This machine employs a static weighing principle, ensuring an accuracy better than ± 0.25%, even at high line speeds. Accurate whole bird weighing is crucial for optimal distribution to further processing stages.

Based on the individual bird weight, the BAADER production software efficiently directs smaller products to the two food service cut-up lines, while larger birds are either designated for retail cut-up or whole bird packing. This precise weighing system guarantees minimal giveaways when packing whole birds and optimizes the use of each bird for cut-up, thereby enhancing productivity and ensuring high-quality output for both food service and retail markets.

In the cut-up phase, both product quality and flexibility are prioritized. The ProFlex Cut-Up system allows for bypassing cutting units based on specific production set-up and incoming sales orders.