MAIN STAGES OF THE SLAUGHTERING PROCESS:
LIVE CHICKEN RECEPTION, SLAUGHTERING AND DEFEATHERING
WEIGHING, QUALITY DETERMINATION AND CUTTING
PACKAGING, STORING AND SHIPMENT
FURTHER PROCESSING DEPARTMENT
1. LIVE CHICKEN RECEPTION, SLAUGHTERING AND DEFEATHERING
Chickens are checked prior to slaughtering in compliance with the legislation in force and the norms of the European Union. When the chickens are brought to the slaughterhouse, their final check is performed by public veterinarians and in-house veterinarians. Upon approval of the veterinarians, the chickens are conveyed to the slaughtering section and the slaughtering process begins. The first phase is the live chicken reception unit. Vehicle carrying the chicken to be slaughtered approach the live chicken reception platform by receiving required information. Plastic crates full of chicken are automatically unloaded from the vehicle and placed on the operating band conveyor. Workers take the chickens from the crates and hang on the carousel. Empty plastic crates and the vehicle are washed and disinfected. The crates are loaded on the vehicles, which leave the slaughterhouse in order to be prepared for the same process in the following slaughtering day.In the meantime, the chickens hanged in shackles are hand-cut by the experienced and trained butchers according to Islamic rites. After that, blood is drained out of the carcass and then scalding process takes place in feather softening tank where chickens are prepared for defeathering. Subsequently, head is removed from the body and the headless carcass transferred to the evisceration line. During transfer process, feet of the chicken are cut using feet cutting machine.
Chickens are conveyed into the evisceration machine, and stomach area of the chicken is perforated. Evisceration machine completely removes internal organs of the chicken which come to the machine. The internal organs continue on the line towards the giblet separation machine, in which intestines and gall bladder are separated. Automation process continues in the subsequent stages. Chickens without internal organs are entered into the throat control machine where maws are removed and the chickens are passed to neck breaking machine. Chickens' necks are removed by the machine. Following removal of the necks, neck skins on the chickens are cut by a machine; and then the chickens are taken into the machine for complete washing including inside and out side. The machine washes inside and outside of the chickens using pressurized spray water. The chickens which are washed are sent to air chilling unit for chilling purposes.
3. AIR CHILLING
Since air chilling process is employed in our plant, microbiological criteria are fully satisfied and the best flavor is achieved. Air cooling units consist of 5 sections containing 3,500 meter long three storey conveyor lines. The chickens enter the air cooling units at 36 degrees temperature and are cooled down to maximum four degrees in the center as they leave the units. The chicken stay in the air chilling units for about 2.5 hours.
4. WEIGHING, QUALITY DETERMINATION AND CUTTING
The chickens which come out of the air chilling unit are passed to an automatic transfer machine equipped with a scale, where they are both weighed and transferred to the determination unit. The chickens which are weighed pass through the quality classification station and then fall into grammaging sections in accordance with the weight ranges and the qualities determined in the computer. The chickens which fall into the pans are first bagged and then packaged as whole carcass and sent to the stockroom. The chickens to be chopped do not fall into the pans and continue their way hanging on the conveyor. Then they are transferred to the cutting line via automatic transfer machine, and are delivered to the cutting modules based on the products to be produced. Pieces of the chopped chickens are separated into their respective sections, controlled for one last time, packaged and quickly taken to cold storage rooms.
5. FURTHER PROCESSING
Certain portion of the products produced at the cutting department is send to delicatessen units for further processing. In the further processing pre-preparation department, raw materials are transformed into mixtures in accordance with the product formulations. This mixture is shaped in automatic machines using the moulds designed for that particular product, and then conveyed to cooking department following liquid and dry coating. Cooking stage is a computer controlled process divided into two phases: fry cooking and steam cooking. Fully cooked products are taken into multi-storey freezer with -40°C ambient temperature, and internal temperature of the product is brought to -18°C. The product is then packaged and stored in deep-freezes until shipment. Delicatessen production consists of pre-preparation, cooking and packaging phases. Mixture prepared in the pre-preparation department in accordance with the product formulation are automatically filled by filling machines, taken to cooking carts and cooked in ovens under computerized control system. The products are first taken into resting units and then packaged and stored in cool storages until shipment. The storage consists of two sections called fresh and frozen. The products are monitored under computerized environment based on first-in-first-out principle. The products in the storages are shipped to the dealers by freezer trucks, which are washed and disinfected.