Life bird arrival department

2017-10-10T10:04:50+02:00

Life bird arrival department

Anlieferung

Delivery

The chickens are delivered in containers by truck. In the air-conditioned lairage the animals have a two-hour rest phase to calm them. The room is lit with only blue light, which chickens cannot see. After the containers have been unloaded the trucks are cleaned and disinfected. The unloading of the containers is fully automated. The animals slide onto a wide, slow-moving trampoline conveyor belt. Optical detectors monitor the containers to ensure that they are completely emptied. The emptied containers are cleaned and disinfected in the subsequent washing line and are prepared for the next transport.

Betaeubung

Stunning

A particular concern of ours is to ensure that the slaughtering process is as stress-free as possible. The animals are gently stunned, before the actual slaughtering process begins. At the end of the stunning tunnel is the so-called carousel. Here the chickens are hung from an endless chain by their feet. As the animals are stunned, this process is stress-free, not only for the animals but also for the employees. This also minimises dust development. Each employee can adjust their individual working height with platforms, enabling us to provide ergonomically optimum working conditions. The gas stunning method has been included in the new Animal Welfare Slaughtering Regulations (“Tierschutzschlachtverordnung”), which will come into force in 2013.

Automatische Qualitaetssicherung

Automatic quality assurance

After they have been slaughtered the chickens pass through the so-called scalders, which facilitates the subsequent feather plucking, which is also fully-automated. Immediately afterwards, the chickens pass a camera system, which compares the quality of the animals with a specified standard.

Evisceration department

2017-10-10T10:05:14+02:00

Evisceration department

“Oven-ready” means that the chickens are ready to cook. They are plucked, gutted, the giblets are “harvested”, as we say in the trade, and both the chicken and the giblets are checked for possible diseases. The chickens pass through various control stations. The official animal inspection is carried out by veterinarians and controllers of the local authority. The carcasses and their innards, the giblets, are checked and defective ones are removed. The giblets are then separated mechanically and the heart, liver and stomach are further processed.

Kontrollstationen

Control stations

At the first two control stations the breast side of the chicken is examined by official controllers. This includes checking them for mechanical damage caused by the scalding/plucking, such as broken bones or colour differences on their skin. The chicken then pass through the machines that harvest the giblets. At the second control station, the chickens and giblets are checked. This time the official controller views the chicken from behind and the corresponding packet of giblets. The meat inspectors are trained by the veterinary inspection office.

Kuehlung

Chilling

The gutted chickens are hung from an overhead conveyor on chilling hooks. Before they pass into the chilling unit, an employee checks the carcass again to ensure it is in perfect condition. In the chiller unit the chickens are chilled to below 2°C within 3 hours.

Cut-up department

2017-10-10T14:36:14+02:00

Cut-up department

Only a small number of the slaughtered chickens leave the company whole. The chicken cutting is mostly automated, due to the uniform anatomy and technical developments based on this. Most of the meat is prepared for the self-service counters in retail food stores.

Zerlegung

Wing, breast (fillet) and leg/thigh products are cut at various consecutive modules and are placed on conveyor belts. It takes between 6 and 8 minutes to cut up a chicken into the various pieces (jointing).

Zerlegung
Zerlegung

The wing and leg pieces are weighed, portioned and manually placed in trays. In the case of chicken breasts, or fillets, this work is done by “pick robots”, which portion the pieces in trays with gram-precision.

Zerlegung

The cutting and further processing of the chicken takes place in chilled rooms. Maintenance of the cold chain as well as process and personal hygiene are decisive for perfect microbiology and therefore for the storage quality of our products. Apart from hygiene clothing, we also provide all employees with thermal clothing. Regular breaks (every 2 hours), rotation at the workplaces and the ergonomic design of the activities, to name just a few factors, are important parameters for optimum working conditions.

Packaging and dispatch department

2017-10-10T10:14:25+02:00

Packaging and dispatch department

Most of our products are “trayed” for the retail market.

Verpackung

The transport of the trays from the cutting through to the packaging machine is fully-automated. The temperature in the packaging department is 2 °C, to ensure an uninterrupted cold chain.

Verpackung

The trays are sealed with protective film and are then weighed and labelled. The batch number printed on the label ensures traceability.

Verpackung

The packing of the sealed trays into transport boxes, stacking the cardboard boxes and moving the stacks of boxes is partly automated. Here a robot picks up the stacked boxes and moves them onto a transport pallet.

Verpackung

In the dispatch department the goods are picked for the individual customers and are then loaded onto refrigerated trucks. The dispatch area and the interior of the truck are chilled to around 0°C. Each day, more than 500,000 packs leave the production facilities of Emsland Frischgeflügel and Celler Land Frischgeflügel and are in the refrigerated cabinets of food retail outlets on the next day.

Further processing

2017-10-10T10:13:58+02:00

Further processing

The study of a large food corporation “So is(s)t Deutschland” (How Germany eats) in 2011 found the following: “The de-structuring of everyday life continues to increase. People eat when they have time for it.” And then, in most cases, it has to be quick. Because of the short cooking times, chicken meat has inherently good properties for these altered eating habits. Life is made even easier for consumers with ready-to-cook or convenience products, which, as the name says, only have to be placed in the pan or put in the oven.

Weiterverarbeitung
Weiterverarbeitung
Weiterverarbeitung

Our product range includes various seasoned and spiced products for barbeque grills, skewered inner fillet, grill joints made from thigh meat, escalopes made from breast fillet that are ready to eat within minutes, oven trays or unseasoned chicken pieces, and chicken cut and prepared for casseroles and fricassees. The main season in the preparation department is the barbeque season, from just before Easter until the end of September.

Weiterverarbeitung

The products are seasoned in “tumblers”, which have a capacity of up to 600 kg. The liquid marinade is automatically metered and added according to the recipe and the batch is mixed within a few minutes. The recipes and dishes are developed in cooperation with our customers. Paprika, curry and herbs are the favourites in the popularity rankings.

Weiterverarbeitung

Some special customer wishes still require manual work. Here, different chicken pieces are placed in a tray. The employees are trained to ensure a visually, sensorially and microbiologically perfect product is obtained at the end.

Innovations

2018-03-20T16:41:27+01:00

Innovation

The word innovation comes from the Latin verb innovare and means to renew. This simply describes what innovations are about. First, analyses and studies of the current situation are carried out in advance. The findings from these are collated and evaluated.

The decisions derived from this can then either lead to new techniques and technologies, or familiar techniques and technologies can be re-used. In both cases, we renew. We consider innovation to be a decisive key to success and competitiveness. It is not necessary to continuously re-invent the wheel; however, it is important to move forward with the help of the wheel. Within the Rothkötter Group, innovations are definitely one of the factors that have led to our competitive and sustainable market position.

Our considerations are focused on improving quality and increasing efficiency. Although consumer protection, health and safety at work, animal welfare and environmental protection are also important elements. It is sometimes small things that have large effects, such as the suggestions of our employees within the scope of the “Top Tip” scheme. Sometimes it is new scientific findings or developments, which arise through intensive exchange with machine manufacturers.

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