The new AeroScalder at Delmon’s poultry processing plant in Bahrain is delivering outstanding results after only a few weeks operation. Aatef Alsaleh, Chief Operating Officer, is enthusiastic: “Our ambition was to improve product quality while addressing cross-contamination and reducing water and energy. For Delmon, the AeroScalder was the right technology at the right moment.”
“We chose AeroScalder to keep our high quality. Achieving the perfect feather-free finish was difficult with our previous equipment due to temperature control issues. The AeroScalder offers superior temperature control, uses less water and energy, and ensures a hygienic process, minimizing the risk of cross-contamination while preserving chicken quality.”
“A major benefit is the shorter startup time. Previously, preparation work with our immersion scalder began at midnight to start production at 5:00 AM. With the AeroScalder, the process takes just 40 minutes. Now, staff starts at 4:30 AM, saving hours and energy. The AeroScalder also helps us take the right steps to ensure hygiene from the start. When you immerse thousands of chickens per hour in the same water, bacteria can spread easily. Now, products have no direct contact, virtually eliminating cross-contamination. We process 5,200 bph, 40,000 birds daily, after which cleaning the AeroScalder takes just 40 minutes. It is convenient that various internal parts are self-cleaning except for the body and some other elements. Unlike our old scalder tank, which required extensive water drainage and had tight spaces and difficult spots, the AeroScalder is much friendlier. Operators can easily enter, wash, inspect, and disinfect without hassle, making the cleaning process fast, easy, and efficient.”
“It takes only a few minutes to teach someone to operate the machine. The interface is very user-friendly, featuring an intuitive control touchscreen that clearly displays the machine’s operations. We can adjust the temperature simply by pressing the screen, and the effect is almost immediate. With our previous system, changes took up to 30 minutes to take effect, and the cooling down process was tedious. Usually, we determine the average flock weight and set the AeroScalder for the entire day. Its design, with moisturized air spraying, hot water circulation, pumps, and sensors, ensures precise control. The temperature stays stable, with fluctuations within ±0.3°C, never exceeding a 1°C tolerance.”
“Our market requires white chicken with no feathers and absolutely no epidermis. So high scalding is needed, meaning burning off the epidermis. However, with high-temperature immersion scalding you risk cooking the meat. One of the nice things about the AeroScalder is that it directs humidified air only where the feathers are, under the wings and the tail and not at the breast. So, there’s no cooking of the fillets beneath the breast with much nicer pink meat as a result. This is perfect for Delmon, as we are increasing cut-up and deboned products.
Since switching to the AeroScalder, we’ve seen significant plucking improvements—especially with the hard-to-remove wing feathers. Before, two employees checked and manually removed leftover feathers from the wing tips after the pluckers. Now, we save those labor costs too.”
The AeroScalder offers superior temperature control, uses less water and energy, and ensures a hygienic process.
Aatef Alsaleh
Delmon Chief Operating Officer
“The government imposes sustainability rules on all the Bahraini companies and allows a maximum amount of water consumption. With the AeroScalder our water savings align with our commitment to environmentally friendly practices and allow us to be one of the leaders in the country’s water saving plan.”
Founded in 1980, Delmon Poultry is based in Al Hamalah. The company also operates a feed mill and hatchery. “What truly sets Delmon apart is our deep local roots. Our workforce of about 250 employees is almost 100% Bahraini, including those ensuring strict adherence to Halal standards. In Bahrain’s close community of 1.7 million people, customers know the people who process their food personally, whether it’s a friend, cousin, or neighbor. This fosters trust and loyalty.” Aatef Alsaleh concludes, “Our customer base includes both horeca and retail sectors. As Bahrain’s sole poultry processor, we consistently experience high demand for our products. By noon, our entire day’s stock is distributed efficiently, ensuring that Delmon’s chickens are readily available to meet demand from the marketplace.”
Dawajen Delmon company site
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