New Processing Facility
Hawley Associates have over 30 years experience in helping poultry processing companies develop and improve performance and profitability.
We are unique and specialist international poultry processing consultants that are not affiliated with any poultry processing equipment manufacturer. We are ideally placed to develop your new poultry processing facility in the most cost effective and efficient manor.
Industry leading Stork Nu-Tech Nuova eviscerator
We understand the importance of quality, yield, productivity and throughput. We also understand that no single equipment supplier has suitable solutions for every requirement or budget.
Over the last 30 years we have helped the poultry processing industry to develop from typical line speeds of 1,000 - 2,000 birds per hour up to today’s fastest high-speed throughputs of 12,000 birds per hour. We understand the pros and cons of automation at every stage & process within a poultry processing factory. We don’t just consider labour savings when recommending automated systems but consider yield, maintenance costs and affordability.
Our expertise doesn’t just include primary poultry processing equipment and process design, but it also covers all aspects from live bird transportation, right through to finished product dispatch including:
Live Bird Transportation and Factory Reception
Different countries and differing throughputs require different solutions with regard to live bird transport and reception requirements. We will fully evaluate your requirements and local environment to ensure that the most practical and cost effective solutions are progressed.
Kill, Scald and De-Feathering Systems
We are experts in scalding and plucking poultry at line speeds between 1,000 – 12,000 birds per hour. Few understand the importance of getting every piece of equipment on the kill, scald and de-feathering line working in perfect harmony. Whether producing soft scald birds for air chilled products or hard scald for water chilled products, ultimately your yield losses start here. It is vital to design this area to work perfectly using the most suitable equipment to fulfil your requirements.
Evisceration
Hand evisceration or automated? Often this is an easy question to answer as it generally depends on line speed and the cost/availability of local labour. Just about every aspect of poultry evisceration can be automated but it isn’t always cost effective in every market. For example, automatic transfer between lines is often recommended by equipment manufacturers on higher line speeds but, in low labour cost countries, often the cost of maintenance alone is more that the labour costs saved. We will use all our experience to make sure you have only the most cost effective systems installed, and this can vary greatly depending upon your location on final products.
Air Chill – Water Chill
Generally, this is dependant on whether the end product is fresh or frozen but not always so. Air chillers are normally on-line systems for higher speed operations. Usually single bird shackles are used, however multi-bird shackles may well be suitable depending upon local factors. Air chillers not only generate a yield loss but also use high amounts of electricity. These factors need to be considered if you are located in a developing country. Water chilling is usually employed for frozen products. A yield gain is achieved as well as a relative quick chill time, however high levels of water are needed. Both yield loss or yield gain are directly influenced by plucking room performance.
Packing Room
Fresh or frozen, whole bird or portions, or a mix of all? What ever your final product requirement, you can be assured that we have seen it before and designed packing rooms to deal with it efficiently. Whether you have a simple low volume product mix, a complex mix of high volume end products, or you are producing weigh-priced products or fixed weight portion packs, we have the experience and expertise to develop the most practical operations.
Cut up, De-Boning & Further Processing
Highly experienced in all aspects including:
- hand cut-up and de-boning
- fully automated systems
- tumbling, massaging and marinating
- forming, crumbing and flash frying
We take great care to make sure that your product flows through processes as efficiently as possible by utilising conveyors, weigh graders and overhead conveyors.
Freezing
We are experts in freezing technology for both whole birds and portions. Volumes from a few hundred birds per hour right up to 12,000 birds per hour. We know the ideal solution for product type and market place.
Waste Removal & Storage
An area often neglected in factory development is the area of waste removal and storage. Significant waste is generated in the de-feathering and evisceration departments as well as cut-up and de-boning. We will make sure that you extract the maximum value from any generated waste by removing it and storing it in a correct manor as necessary.
Services
Every item of equipment installed in the factory will require services such as gas, electricity, water, steam, compressed air, vacuum or drainage. We will work with your architects and builders to make sure that all the required services are laid on to each piece of equipment.
Building
From country to country different building styles and standards apply. However, having been involved in many hundreds of poultry processing projects, we understand how to construct a suitable building quickly and efficiently regardless of the environment of your location. We will use this expertise to advise and guide your architects in the building design and construction materials to ensure that you have the perfect structure for housing a hygienic poultry processing operation.
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