100% commitment

To do all this stuff is incredible and beyond anything I could ever dream of

SCOTT SECHLER

to produce only premium chicken products

US premium poultry processor Bell & Evans sells its premium products mainly on the domestic retail market. Always pursuing the highest quality product, Bell & Evans’ new greenfi eld facility in Fredericksburg is no exception. Owner Scott Sechler about his new processing plant: ‘Every machine purchased was meticulously selected to achieve superior quality, sustainability, effi ciency, traceability, safety and humane handling of our chickens.’

WWhile designing a new facility through a global pandemic wasn’t ideal, it played a big role in how the engineering itself all took place. A 3D version of the facility was put together so all aspects could be talked through, point by point. From wiring to drain placement to equipment design and layout, nothing was missed during the engineering phase, making the building phase much smoother. ‘To do all this stuff is incredible and beyond anything I could ever dream of’, says Scott Sechler. The new plant is Sechler’s vision of how chicken processing should look. Automation replaces the most labour-intensive jobs where it doesn’t make sense to have human labour. Marel has fully equipped the processing plant, including two processing lines, each with a capacity of 8,400 birds per hour, but prepared for even higher speeds.

Humane treatment

Chicken well-being is a priority in Bell & Evans’ 100% Rule. For more than 20 years, their chickens have been raised without antibiotics and within a unique, low-stress management system from egg to farm to processing and transportation. Bell & Evans’ standards signifi cantly exceed those of USDA Certifi ed Organic. The company focuses on animal well-being during transport from farm to processing plant. Its farms are located less than an hour’s drive, on average, from the processing facility and chickens are transported in state-of-the-art live bird transportation systems.

Minimise stress

As Bell & Evans’ aim is to handle its chickens with the utmost care, the company purchased the ATLAS automated transport system. This system eliminates the use of forklifts and minimises stress during unload. The reduction of noise, light, sound and movement off ers a smooth transition from the trailer into anesthetization. As humane anesthesia was high on the priorities for the new processing plant, it was an easy decision to opt for multistage CAS SmoothFlow anesthetization. Scott Sechler: ‘This plant is completely built from the standpoint of animal welfare to be the best ever. The human welfare to be the best ever. And the quality we produce to be the best ever.’

Air chilling

Another key point of difference is air chilling. Other US poultry processors produce chlorinated water chilled chicken or use a mix of water and air chilling. Since 2005, the company has utilised 100% air chilling, a unique first in the industry. ‘The reason why is obvious’, Scott Sechler notes. ‘Air chilling is a significant contributor to the tenderness and flavour of the meat as compared to the conventional water chilling system. Our 100% Air Chilled method means no need for chlorinated ice water, so chickens‘ natural juices never get diluted or replaced. Air chilling nets a better product. Besides that, it also reduces handling and environmental waste.’ Air chilling is Bell & Evans’ way to transform US food processing and provide another level of quality to the consumer.

European-like

After air chilling, products are distributed and cut up, including a Q-Wing solution for wing part selection. Scott Sechler mentions wings and how everyone wants them, but they get easily damaged. With this technology, he’s expecting ‘20% to 40% more grade A wings.’ Unique to the US are the automated in-line thigh and drumstick deboning systems, already an upcoming trend in Europe. ‘In fact, we’re a European-

Air chilling nets a better product

minded company that’s located in the United States.’

Traceability from farm to fork

Bell & Evans also commits 100% to traceability. Right from entering the processing plant until packaging, each chicken can be traced back in the process down to which flock and which farm it came from. The Innova food processing software not only ensures this traceability program but will also connect all solutions throughout the plant, collect and analyse data and offer plant staff the information they need to run highly efficient operations. ‘Marel is the only company in the world that has all the pieces figured out and in place together to offer a truly remarkable poultry processing system that I’m proud to use in our new processing plant’, concludes Scott Sechler.