As consumer demands for sustainability, efficiency and animal welfare continue to reshape the poultry industry, the latest trends in evisceration systems are taking center stage. From automated evisceration lines equipped with data-driven precision to eco-friendly waste management solutions, these advancements are not just increasing productivity, they’re redefining the very standards of the industry.

“There is no longer much human technological knowledge needed for optimal eviscerator performance; it is now data-driven,” said Randy Wilson, industry sales manager for poultry for Marel, the Iceland-based company, with US offices in Lenexa, Kan. “Evisceration is all about intelligent equipment in a 2024 world.”

Today’s evisceration lines are already highly automated, and these technologies also allow for greater production speed and more streamlined operations, contributing to both efficiency and product consistency.

Still, modern systems demand a blend of mechanical and electronic expertise, particularly for maintenance and troubleshooting.

Making a Difference

Earlier this year, Marel released the Nuova-i, an intelligent eviscerator that counts its own performance on every module, every resolution and there’s an HMI (human-machine interface) touchscreen on the machine or remote dashboard that tells the processor how every module is doing on every resolution.

“Technological advancements allow the Nuova-i to efficiently separate viscera packs from the carcass,” Wilson said. “This results in uniform and compact viscera packs, leading to increased yield, cleaner carcasses and enhanced hygiene standards. It can make on-the-fly adjustments on its own.”

Consequently, the risk of cross-contamination from loose hanging intestines, which may come in contact with each other, will be nearly eliminated.

“Additionally, the size or shape of a broiler flock will no longer pose a challenge,” he said. “The distance between shoulders can be adjusted, and the shackle guide can accommodate both long and short feet. The sturdy spoon ensures precise positioning and movement, handling the task with great care.”

Furthermore, once a recipe setting has proven to be successful for certain flock characteristics, the Nuova-i will remember this flock setting with a single tap on the screen and all relevant eviscerator settings will adjust themselves accordingly. This results in a smooth and constant process flow.

“We can run up to 250 birds per minute on a single line in certain criteria, and it’s approved by USDA,” Wilson said.

The Baader evisceration line includes integrated data-capturing devices that enable real-time production monitoring and optimization.

“These devices allow processors to make data-driven adjustments on the fly, improving throughput and minimizing downtime,” said Oliver Hahn chief executive officer of Baader Food Systems USA Inc., based in Kansas City, Kan. “Additionally, real-time data monitoring helps management track utility consumption (i.e. water and energy) and identify maintenance issues before they become critical, leading to increased operational efficiency and reduced costs.”

The Nuova-i from Marel is an intelligent eviscerator that can make on-the-fly adjustments on its own. (Source: Marel)

Impact on Safety

Baader’s latest evisceration systems enhance safety and hygiene through intelligent monitoring and automated alert systems. For example, the system logs safety concerns and provides real-time notifications via the HMI and visual indicators directly on the machine. This proactive approach reduces human error and ensures that any safety issues are addressed promptly and effectively.

“Furthermore, the system is built to the highest hygienic standards, incorporating easy-to-clean designs that meet or exceed regulatory requirements, reducing the risk of contamination and improving overall food safety,” Hahn said.

Wilson said under MPIS, the government doesn’t care how the bird carcass gets clean, as long as it’s clean at the end of the process. This allows customers to take some shortcuts, however, it’s bad for the harvest. The newer tech and processes eliminate the issues.

“It’s about separating people from equipment, making a better environment and just having clean carcasses at the end of the day,” he said. “It has a huge impact on safety.”

Overcoming Challenges

One of the main challenges plant operators face when adopting data-capturing technologies is ensuring a secure and reliable IT infrastructure to handle the data gathered. Therefore, more processors are investing in cybersecurity measures and advanced networking solutions to protect their operational data.

Many evisceration technologies also address sustainability and environmental concerns associated with poultry processing.

“The Baader evisceration line can monitor and control water consumption automatically based on bird detection sensors,” Hahn said. “By continuously monitoring and adjusting resource usage, Baader helps reduce our customers’ environmental impact ensuring a sustainable production.”

The perception of quality and taste remain largely unchanged, however the concept of product traceability is a growing consumer demand.

“Consumers want to know more about the origins and processing of their food,” Hahn said. “Technologies that allow for greater traceability, such as those that track the production process in real-time, can enhance consumer trust and confidence in product safety and quality, even if the taste remains the same.”

Some special training is required, but most in the industry can adapt relatively quickly.

“You have to have skilled technicians, and we ask too much of maintenance departments,” Wilson said. “Today, those technicians, after a year or two of running, have to do different levels of rebuilds on the equipment. We basically ask them to take the machines apart and rebuild them on the production floor over a weekend and then expect it to perform perfectly upon startup.”

Marel has started a module swap program that can help in this regard. It asks that customers buy a complete second set of modules for each machine, so when it’s time to do the major rebuild, the whole evisceration line can be built in one day. The company takes the used ones back to be rebuilt to factory specifications and returned to the processor for the next go-around.

Looking Ahead

The future of poultry processing will likely see a continued emphasis on higher efficiency, enhanced quality and more predictive maintenance.

“It’s just going to be more and more, with AI possibly making a difference as well,” Wilson said. “The technology is coming fast and it’s a big improvement.”