KemperKip: Balancing Traditional Process
Methods with Automatic Filleting Efficiency

This continuous innovation in product development has been KemperKip’s ‘secret’ weapon, driving growth in this niche market. As the demand for organic chicken meat surged across Europe over the past decades, it has recently stabilized, intensifying competition among producers vying for consumers willing to pay a premium for organic, slow-grown chicken.

‍

Battling High Labour Turnover and Costs

KemperKip stands out with its commitment to best quality and long shelf-life, achieved through meticulous feeding, farming, and semi-traditional processing methods. However, maintaining these traditional, manual operations requires skilled personnel. With salaries rising nearly 13% over a couple of years, KemperKip has faced challenges with high labour costs and turnover. Despite these challenges, KemperKip continues to uphold its tradition of excellence, navigating the complexities of the modern market while staying true to its values of quality and great taste.

At KemperKip, skilled manual labour is essential to achieve the highest meat quality and yield. However, this process requires extensive training, and new, untrained personnel are often slower and less accurate in the cutting process.

“As a small-scale, traditional processor dedicated to producing quality products, frequent changes in personnel make us particularly vulnerable. Manual processing is also time-consuming and can lead to longer delivery times. Faced with these challenges, we recognized the need for an automated breast filleting solution that would not compromise our high standards of quality. However, the size variations of our breast caps posed a significant difficulty for standard automatic solutions, as most options we explored tended to cut into the meat, which is unacceptable for KemperKip. Finding an automated system that could handle the size variations of our breast caps without compromising on quality was crucial. At KemperKip, we are committed to upholding our legacy of excellence, and this commitment extends to every step of our production process, including the integration of automation in a way that preserves the artisanal quality of our products”, explains Henri Verstappen, Managing Director at KemperKip.

Looking for an Automatic Solution that Protects Quality

While grappling with labour challenges, KemperKip attended the annual assembly of NEPLUVI, the Dutch Poultry Processing Association. There, they met Jos Bongers, BAADER’s Area Sales Manager for The Netherlands. After hearing about KemperKip’s issues with the significant variation in breast cap sizes, Jos invited them to test their own products on the BAADER Breast Cap Deboner 660A.

This flexible deboning machine measures the size of each breast cap and adjusts the scraping and cutting tools accordingly, accommodating variations without compromising quality. With the Breast Cap Deboner 660A, KemperKip could efficiently produce fillets using only two manual loaders, while the rest of the process would be fully automated.

When KemperKip tested their own breast caps on the Breast Cap Deboner 660A, the results were convincing. The transition to automated filleting would maintain their best-quality product standards. However, accurate calculations were still necessary to determine the machine’s return on investment.

“We needed to assess whether the reduced labour dependence and faster delivery times would justify the investment. After thorough analysis, the conclusion was clear: The solution would uphold our high standards and protect our family brand. It would bring peace of mind, knowing that we could consistently deliver fresh fillet products quickly and efficiently to our loyal customer base”, says Henri Verstappen.

‍

‍

Smooth Implementation

Once the decision was made, KemperKip wanted to implement the solution as quickly as possible. Within just three months, they had received the machine, completed the training, and were producing their first fillets.

“We have limited space for installing large machines. Fortunately, the machine’s compact footprint allowed us to adjust some walls and create an ideal space for deboning. The machine is easy to use, and our personnel have adapted well to the new processes. They appreciate the flexibility it brings to their work, when we receive orders for fillets”, says Joris Kemper, Commercial Manager at KemperKip. “Since the implementation of the machine, we have observed significantly better yields, as indicated by the carcass weights after filleting,” he continues with a smile.

‍

Prepared For Future Developments

“Currently, we produce skinless single fillets with the tender attached, but the machine gives us the capability to produce other fillet products using pre-set recipes. Some customers are requesting smaller package sizes, so, we are considering offering tender-off fillets as an alternative. It’s crucial that the new machine supports the continued development of our product portfolio and thereby our company’, says Joris Kemper.

By integrating the BAADER Breast Cap Deboner 660A, KemperKip continues to honour its legacy of excellence while embracing innovation to meet modern market demands. We look forward to supporting this visionary processor in the years ahead and wish them continued success in their family-led journey.