Sealed Air demonstrated a new, integrated equipment and material solution for whole bird packaging at the International Production and Processing Expo (IPPE) at the Georgia World Congress Center in Atlanta, Georgia, on January 30 – February 1, 2018. The Sealed Air display featured an operational, fully-automated whole bird line, enhanced by an online cost calculator to help demonstrate this system’s rapid return on investment for poultry processors.

In today’s food processing environment, workforce instability creates annual employee turnover rates consistently above 70 percent, resulting in a significant loss of time, money and resources. In fact, according to an industry report, labor accounts for approximately 60 percent of the total cost in a food processing plant. As the market demand and price for roasters and broilers fluctuate, it will be increasingly difficult for processors to maintain efficiency and protect their margins. Further, the production disruption and lack of skilled workers put food quality and food safety at risk, impacting all players along the food supply chain.

Cryovac Whole Bird Automation Systems help processors balance the need for packaging that meets consumer expectations for shelf-appeal and food safety with the need to also package birds efficiently and cost-effectively.

“We understand that challenges in operational efficiency can lead to increased waste and impact our customers’ ability to be profitable,” said Larry Churchwell, North American Marketing Director for Poultry at Sealed Air Food Care. “By helping our customers automate the most physically demanding aspects of their processes, we can help them get more functional hours out of their production shifts while improving product quality and food safety.”

Cryovac Whole Bird Automation Systems automate the most labor-intensive tasks of packaging whole poultry such as hock breaking, bag loading, and vacuum sealing. System components include the Cryovac HBX Series Hockbreaker, the Cryovac BL220 Automatic Bag Loader, the Cryovac 8600E Series Rotary Chamber Vacuum System and the Cryovac ST101 Shrink Tunnel. By integrating these four pieces of equipment with a proprietary shackle line and conveyor system, Cryovac Whole Bird Automation Systems allow one operator to package an average of 45 birds per minute.

As for meeting the needs of consumers, Churchwell said, “Having a leak-proof package for poultry is crucial at the point of sale and for controlling purge, because consumers see it as a food safety issue. Additionally, our easy-open Grip and Tear technology eliminates the need for scissors or knives which further increases safety and reduces contamination.”

For more information, visit: www.sealedair.com.