Thailand is one of the world’s major poultry exporters, supplying products to Japan, the EU, the Middle East and ASEAN countries. This project is built strictly in accordance with Thailand DLD (Department of Livestock Development) standards and meets international export HACCP hygiene requirements.

[IMAGE: 项目信息图，产能、合规标准、流程概览]

Client Background

The customer owns a complete industrial chain including breeding farms, hatcheries and feed mills. This expansion project aims to boost export-oriented production capacity to satisfy stable overseas orders.

Their original production line ran at 6,000 BPH and faced obvious bottlenecks:

1. Traditional manual crate unloading caused bird bruising and high DOA rate, which reduced finished product qualification rate for export.
2. Offal sorting, cleaning and inspection relied heavily on manual work. It was difficult to keep stable hygiene standards and consistent processing speed at high capacity.
3. Manual portion trimming could not meet the strict weight and appearance requirements of EU and Japanese buyers.
4. They required a unified, smooth end-to-end production flow from live bird intake through to finished portion products, with strict separation of hygienic zones to satisfy export food safety rules.

After comparison with multiple suppliers, they chose our turnkey solution. Our strength lies in the overall plant layout, main overhead slaughter line design, hygienic zone separation, CIP cleaning system and full on-site project execution, to build a seamless high-capacity processing workflow for export-grade chicken products.

[IMAGE: 客户旧车间实拍，升级前生产场景]

Our Solution: Integrated 15,000 BPH Main Processing Line

We designed the whole plant with a continuous overhead shackle rail system, reasonably divided into dirty processing zone and clean processing zone. All our supplied machines adopt food-grade 304 stainless steel, supporting full CIP wash-down cleaning.

1. Live bird receiving & automatic crate unloading section

The front-end adopts a fully automatic crate unloading system for stable, gentle bird handling.

• Automatic depalletizer: automatically transports and separates stacked live bird crates
• Crate tipping & releasing system: birds are unloaded gently to reduce stress, bruising and DOA
• Automatic empty crate washing & restacking: empty crates are sanitized and stacked automatically to circulate back to farms
• Live bird hanging station for shackling onto the main overhead line

[IMAGE: 自动卸笼工位全景]

2. Slaughter, scalding and defeathering section

• Adjustable water bath stunning system, parameters set to fit local halal processing requirements
• Bleeding station with sufficient bleeding time, compatible with halal slaughter specification
• Counter-flow scalding tank with precise temperature control, to guarantee efficient feather removal without skin damage
• Multi-stage feather removing units, including neck and residual feather finishing, stable operation at 15,000 BPH
• Automatic head and feet separation station

[IMAGE: 自动卸笼工位全景]

3. Carcass inspection, washing and offal fine treatment zone

Carcasses are conveyed along the overhead rail for veterinary inspection. After primary evisceration, all visceral materials enter the dedicated offal processing area. This zone is laid out for standardized offal fine handling. Staff complete sorting, cleaning, trimming and quality screening of hearts, livers, gizzards and other by-products following strict hygienic workflows. All qualified offal products are collected for packaging, while unqualified materials are sent to the by-product rendering system. One-way flow design strictly prevents cross-contamination between carcasses and offal.

[IMAGE: 内脏处理区域全景（不特写单机设备）]

4. Two-stage chilling system

Counter-flow immersion chilling system cools carcasses from body temperature down below 4℃ within the required time, which is essential for shelf life and export food safety.

• Pre-chiller for initial heat removal
• Main ice-bank chiller for deep cooling
• Air drying tunnel to remove surface water before entering the finishing workshop

5. Portion finishing workshop

After chilling and drying, carcasses are transferred to the finishing area for standardized portion cutting, trimming and deboning. The workflow can be flexibly switched according to order demand: whole carcass packing, or cutting into wings, leg quarters, breast portions and other specifications. QC staff carry out final inspection to remove bone fragments and defective products. Qualified portions go to vacuum packaging or IQF quick-freezing, then enter the -18℃ finished cold storage.

[IMAGE: 分割整理车间全景，拍摄整体动线，避开设备特写]

6. By-product recovery system

Feathers, blood and other by-products are collected and sent to the rendering system for further processing into feather meal, meat and bone meal, to improve the overall economic benefit of the plant.

Installation, Commissioning & Training

Our engineering team stayed on site for 14 weeks to complete the main line construction:

• Install overhead rail, unloading system, scalding, plucking, chilling and carcass conveying equipment
• Complete water supply, steam, refrigeration and electrical connection, docking with the factory central control system
• Carry out dry run test, and gradually ramp up production speed from low capacity to stable 15,000 BPH
• Train operators on line operation, daily CIP cleaning, temperature record and routine troubleshooting
• Coordinate the whole-line workflow validation across all processing zones, to guarantee smooth handover between each production stage
• Support DLD official inspection and HACCP document submission to obtain export production qualification

We provided English-Thai bilingual operation manuals and long-distance technical support. Local maintenance service is arranged for regular inspection.

[IMAGE: 工程师现场调试主流水线照片]

Project Results

Six months after formal production, the client achieved the expected target:

• Stable operation at 15,000 birds per hour, greatly lifting export production capacity
• Automatic unloading reduced DOA rate from 1.2% to below 0.3%
• Independent zoning and standardized workflow meet strict DLD and EU food hygiene requirements
• Seamless coordination of the full processing flow from live bird intake to finished portions
• Labor input in front-end receiving and slaughter section is reduced significantly
• By-product recycling brings extra income and optimizes overall production cost

“We needed a reliable turnkey partner to build our export-grade high-speed poultry plant. The complete layout and production system they delivered meets all of our strict quality and throughput requirements for overseas buyers.” — Plant Operations Director, Eastern Thailand

[IMAGE: 成品包装禽肉产品，冷库内实拍]

Suitable Customer Groups for This 15,000 BPH Turnkey Solution

This large-scale poultry processing turnkey project is designed for:

• Integrated poultry groups with self-owned breeding farms and export business
• Processors who plan to build new export-grade plants or expand existing high-capacity lines
• Buyers requiring a full, hygienic production workflow including offal refinement and portion finishing
• Enterprises that need DLD, HACCP compliant poultry slaughter facilities in Southeast Asia

We also supply medium and small scale slaughter lines from 500 BPH to 12,000 BPH for regional processors and farm-type plants.