The USA poultry producer Bell & Evans and Iceland-headquartered Marel have signed an agreement to build a greenfield poultry plant in Fredericksburg, Pennsylvania
The agreement, marking one of the leading transactions for Marel to date, is in line with Marel and Bell & Evans’ same vision for sustainability, animal well-being and food safety.
Selling its premium products mainly in the US domestic retail market, Bell & Evans focuses on stimulating the trend towards more sustainable consumption. The greenfield plant is expected to boost the sales of organic chicken products. Marel will fully equip two processing lines, each with a capacity of 140 bpm, prepared for 175 bpm.
Highlighting that the deal is set to add maximum value to the entire chain, Roger Claessens, executive vice-president of Marel Poultry, said, “Bell & Evans recognises that only a strong partnership, covering the entire processing line can raise the quality of poultry processing to the same high level.”
Animal well-being during transport from farm to harvesting plant
Bell & Evans owner Scott Sechler explained that the company is committed to premium and organic chicken. Moving the bar higher than the US regulations, Bell & Evans has the world’s first organic-certified and animal welfare-focused chicken hatchery. In June 2019, Bell & Evans fully transitioned to its ‘Das Klassenbester’ chicken, a grade-A breed of broilers, replacing the existing breed of chickens.
Additionally, Bell & Evans will use Marel’s ATLAS automated transport system to eliminate the use of forklifts and minimises stress during unloading by reducing noise, light, sound and movement to offer a smooth transition from the trailer into its slow induction anaesthesia (SIA).
Marel ACM-NT line to be used after 100 per cent air chill
Unlike the other US poultry processors who produce chlorinated water chilled chicken or use a mix of water and air chilling, Bell & Evans is using 100 per cent air chilling for chicken production. The goal is to transform the US food processing and provide a higher level of quality to the consumer.
After 100 per cent air chill, products are distributed and cut-up in a Marel ACM-NT line, including a Q-Wing solution for wing part selection. Unique to the USA are the automated in-line thigh and drumstick deboning systems, already an upcoming trend in Europe.
Traceability from farm to fork
The traceability process in the Fredericksburg facility is unique to the US. Right from the moment of 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.
Marel’s food processing software Innova aims to ensure this traceability programme and connect all solutions throughout the plant, collecting and analysing data and offer Bell & Evans plant staff the information they need to run efficient operations.
