Reaching the summit in layer processing

Only the top

Rui Crespo, General Manager of Ovolider says, “We saw an opportunity in this market because we have a significant volume of layers for which we previously didn’t have the proper solution. Running a flock of layers alongside regular broilers is never an ideal situation in any processing plant, so a dedicated layer processing was the best option for us.” 
From the hilltop in Boiça, Ovolider strives to be at the summit of the market. Project Director Marco Barros adds, “Just as we are a leading player in the European egg market, our ambition is to become a top European layer processor. To achieve this, we continuously seek out the best available technologies and partners who can meet these standards. As we work with leading suppliers in egg sorting and packing, so we chose to collaborate with JBT Marel because they have proven to be the most technologically advanced and reliable company in the poultry processing industry.”

Tackle the issue

What special processing measures are needed for layers compared to broilers? Marco Barros answers, “Of course, our spent layers differ greatly from regular broilers in weight and shape with thinner legs for example. These are older hens, with tougher carcasses and fully developed ovaries. Although they are at the end of their productive lives, egg production continues, and this is especially visible in the evisceration department. We followed the advice of Marco Solleveld and Carina Portugal from JBT Marel, with whom we developed the full scope of the technical solutions in close collaboration.”

Adapted processing

The line features tailored adaptations for layer processing. JBT Marel equipment covers live bird handling, water-bath stunning, killing, bleeding, scalding, plucking, and rehanging. For scalding, a low-temperature scalding regime has been chosen with special attention being paid to preservation of the epidermis, a key presentation characteristic for Portuguese poultry products.

The evisceration line includes a VC-16 Vent Cutter and VO-20 Opening Machine for hygienic opening, followed by the Nuova CoreTech eviscerator adapted for layer processing, which carefully removes the viscera, including the ovaries. The line continues with NIC Neck Skin Inspection, Neck Cracker, FIM RotoVac, and an I/O Washer.

Whole product or cut-up

Products are then automatically transferred via a TR-EC/G weighing rehanger and tracked throughout the line using PDS-XL. Both products and giblets are chilled in a DownFlow Plus air chiller, providing compensation for the loss of yield. After chilling, products pass through a QS-3 quality grading station and are directed, based on weight and quality, to the whole-bird or cut-up process. Whole birds are unloaded by weight at the drop stations, while selected products are transferred to an ACM-NT cut-up system, which produces half birds, wings, breast caps, and quarter legs. Ovolider sells its chicken products both whole and cut-up, fresh and frozen.