When a large poultry slaughterhouse in the north of Germany started planning two new production lines, it looked for a solution that would improve the giblets extraction process, decrease the amount of handling, and ensure the product looked fresh at the end of the production process. The company, which slaughters around half a million chickens each week, was not satisfied with conventional vacuum systems. Traditional slaughterhouse vacuum systems generally fill a funnel and then pump the contents out with a low-pressure, forceful push. The product is then transported through a pipe network at high speed. This process generates heat, which slightly cooks the chicken meat so that it no longer looks fresh. The second disadvantage of this system is that the intermittent pump operation uses a lot of energy and is a strain on the machinery.
Handling the product with care
Working with Atlas Copco's compressed air and vacuum experts, the company was able to develop a brand new extraction system for its production line. The three GV 1200 vacuum pumps gently extract the giblets almost continuously, rather than intermittently as before. The cyclones, which are tapered at the bottom and specifically designed for this process, ensure the giblets are extracted with minimum energy consumption. As the volume of giblets to be transported is always small, a relatively low level of vacuum is required.
Decreased noise, increased energy-efficiency
Atlas Copco's oil-sealed rotary screw vacuum pumps operate much quieter than other systems. The slaughterhouse operates the pumps at a vacuum of between 900 and 550 mbar or 100 to 450 mbar (absolute) - the optimum energy efficiency level. Two GV pumps supply four filleting lines, while the third pump operates vacuum packing machinery. All three vacuum pumps can be networked if required.
Easy access to data
The company can easily read and adjust pressure data and other parameters on the Atlas Copco vacuum pumps compared to other conventional systems on the market. The programming options for the GV vacuum pumps also make the production process much easier. Pressure bands are simple to program, and it is easy to detect the pressure flow and any leaks in the system. As a result, the entire system can be precisely controlled, ensuring that the valves only open for the required amount of time and only the exact level of vacuum required for the production process is applied. As a result, the system only requires around two-thirds of the energy that other pumps would require.
The GV vacuum pumps are hardwearing and have been working perfectly ever since they were installed a year ago.
Equipment spotlight: GV 1200
- The highest performance output per kW input, the GV outperforms all other vacuum technologies in its pressure range.
- The the modulated valve is fitted directly to the pump inlet to match capacity to demand.
- Plug-and-play installation.
- Space saving canopy.
- Minimal maintenance for maximum uptime.
Written by Michael Gaar