ProFlex cut-up systems

ProFlex Premium or ProFlex Classic as standard plug and play in frame, ProFlex Food Service standard

subsystem with conveyor

2

Single Bird Processing

Protect your live bird investmentGetting the most out of your investment is crucial no matter the size of the production, the need for product mix or weight range of the incoming broilers. Every single bird represents an investment and care needs to be taken through every processing step to protect it.

BAADER LINCO sees it as our distinguished task to supply our customers with cut-up systems that meet the individual

needs of each of our unique customers.

At BAADER LINCO, we divide our cut-up into 2 systems: Pro-Flex Premium and ProFlex Classic. Within these systems, we have multiple possibilities regarding variation and built-in intelligence so we feel confident claiming that the ProFlex cut-up lines virtually fit any processing plant.

3

We act on your needsTell us about your incoming products and your needs for outgoing product mix. We support the largest weight range including a full-blown solution for big birds as well.

Experience countsWe have more than 40 years´ experience in cut-up and more than 400 systems in different countries all over the globe. CustomisingLet us help you get the customised solution that fits your set-up - ask us and we will send a specialist to find the sys-tem that fits your production - we are flexible and capable of adapting to your needs and requirements.

IntelligenceManage the cut-up process by knowing the incoming prod-ucts and use a combination of weight and quality knowl-edge to control the cutting process. We know the weight and quality of every single bird and can direct it to the op-timum process.

Solid foundationThe backbone in the ProFlex cut-up system is our unique shackle. In combination with a simple, strong and durable frame construction and electrical height adjustment, it shapes the perfect base for high speed, high accuracy and high yield.

AFNR / Shutterstock.com

4

Processing big birdsWe have faced improved chicken genetics over the last half-century and our customers are utilising these im-proved genetics to the fullest. This means that we have seen a serious shift in the bird sizes that our equipment has to deal with.

For the dark meat area, new units have been released tak-ing the anatomy of big birds into concern and we have to say that our yields are outstanding and our equipment is built to hold up against the harsh environment it has to endure day in and day out.

Custom-made system to fit in any production

ProFlex cut-up systems offer reliable and precise portion-ing of chickens and rest on a base of solid frames and high-quality units. The ProFlex cut-up systems combine three important key factors: Precision, speed and flexibility and can be purchased in either a Premium or a Classic version.

4 good reasons for purchasing a ProFlex cut-up system ■ Clean, anatomical A-grade cuts for increasing meat yield

and at the same time minimising the costly trimming operations.

■ Optimum high-speed workflow capable of processing up to 7000 birds per hour (Classic 6000 bhp), without compromising the quality.

■ Flexibility to customise a system with maximum level of automation, production capacity and the type of bird or weight range to be processed.

■ Easy to maintain and clean because of the simple construction - this also entails low spare parts consump-tion.

5

ProFlex Premium cut-up systemThe ProFlex Premium system is one of the market’s most ad-vanced cut-up systems for chickens and offers unsurpassed flexibility and efficiency. It automatically cuts up whole birds and drops off the cut pieces exactly where required.

Build your ProFlex cut-up system with intelligent compo-nents and use the bypass option for advanced control of the cut-up process.

ProFlex Classic cut-up systemProFlex Classic is the price-competitive system designed in a complete frame structure with all cabling pre-wired and delivered as a “plug & play” cut-up system with a line speed of up to 6000 birds per hour.

ProFlex Food ServiceSimple, strong and durable ProFlex Food Service solution for cutting birds in order to meet the demands from any fast-food chain.

ProFlex Food Service comes in a system including a flighted conveyor and in its standard configuration it fits perfectly into a container for easy transportation and plug and play installation.

ProFlex Premium ProFlex Classic ProFlex Food Service

Intelligence x

Bypass x

Frame line or flex line x x Frame line

Smooth shackle turn x Option

Electrical height adjustment x Option

Supports all types of units x x x

Shackle Premium Classic Classic / Premium

Standard configuration(12” between shackles) Up to 7000 birds per hour Up to 6000 birds per hour Up to 5000 birds per hour

High-speed configuration(10” between shackles) Up to 8400 birds per hour Up to 7000 birds per hour

14

13

1211

11

10

10

9

87

6

Customise your process with ProFlex Premium

Tail Cutter Wing Tip Cutter Mid-joint Cutter Whole Wing Cutter Breast Pre-Cutter1 2 3 4 5

Leg ReleaserThigh/Drumstick Cutter w/ bypass

Leg Releaser Selective Shackle Washer

11 12 13 14

6

5

1

4

3

2

7

The ProFlex Premium system is a high-speed system capa-ble of handling up to 7000 birds per hour on the standard 12-inch pitch. ProFlex Premium can be arranged to fit exist-ing plant layout.

Anatomical and clean cuttingThe ProFlex Premium system observes the well-established BAADER LINCO principles for clean cutting, flexibility and performance. Cut-up can be done in anatomical portions, e.g. 3-piece wing cuts and thigh/drumstick cuts. Following the cut-up, the individual pieces are automatically distrib-uted to selected drop-off stations for batching, deboning, filleting or further processing.*

Up to 24 pieces availableThe Proflex Premium system uses every part of the chicken and hereby maximises yield. With the possibility of dividing a chicken into as many as 24 different pieces, the ProFlex system is capable of satisfying every demand from any mar-ket and region in the world.

Even higher capacityThe standard pitch is 12 inches, but if a higher capacity is needed, we have the option to use a 10-inch pitch. Using a 10-inch pitch means increasing the capacity of ProFlex Pre-mium of up to 140 birds per minute / 8400 birds per hour. This option comes with a restriction, because not all units fit the 10-inch pitch and need prequalification.

Front Half CutterBreast Cap Cutter Carcass Cutter Leg quarterLeg Processor

w/ bypass

*Please consult “Catalogue of ProFlex units” for more detailed information about units.

6 7 8 9 10

8

The intelligent ProFlex Premium

We automatically control Single Bird Processing through the knowledge of weight and quality. Our B’Logic® soft-ware gives us the ability to distribute the birds to the right spot through our selective transfers and bypasses.

Bypassing units is the heart of the intelligent ProFlex Pre-mium. Thanks to our unique shackle design, the ProFlex Premium system can bypass all types of cut-up units no matter the position of the shackles. This is done in the shackle with no guide bar touching the chicken.

Balanced production planningOptimised production depends on three factors: flock char-acteristics, sales forecasts and production capacities. We process each bird according to these three factors; this is what we call Single Bird Processing.

The key components in effective control of the cut-up for a balanced production planning are: ■ Weigh Transfer ■ ClassifEYE - vision system ■ Selective Transfer ■ B’Logic® software

Bypass is the heart in a balanced production planning

9

Accurate single bird weightOur weigh transfer technology offers an accurate weight of each bird (± 0.25 %) which will contribute to determining the optimal further process of each individual bird.

Quality grade detection with ClassifEYE®Our ClassifEYE® vision system will capture possible defects on each bird at high-speed processing. The ClassifEYE® gives you valuable information about your process; upstream to-wards farmers and first processing and downstream equally important. The individual grade obtained from ClassifEYE® will indicate how the bird should be used in the best way possible in production downstream.

Best-fit productionHaving obtained accurate weight and quality grade of each bird our new Selective Transfer distributes the birds in ac-cordance with order intake and bird characteristics optimis-ing the utilisation of each bird and order fulfilment.

Stay on track with B’Logic®Our B’Logic® software presents key production figures cap-tured on the shop floor. If the captured figures deviate too much from specified target values, the software will give im-mediate notifications on an office PC or on mobile devices. Being aware of the deviation allows for corrective actions that bring production back on track.

Protect your live bird investment by maximising the utilisation of every single bird in a balanced and flexible process

6

5

1

4 4 4

2 3

10

We can design the optimum workflow to maximise the out-put of the intelligent ProFlex Premium. If you want to be able to plan ahead the key is knowing the incoming products early in the process to make the best distribution of the raw material.

In the below example, a ProFlex Premium and a ProFlex Pre-mium Food Service cut-up are combined with a distribution system. When we transfer from evisceration to cooling, we weigh the bird and make visual trend evaluation giving us an indication of both weight and quality 3 hours ahead of cut-up and whole bird distribution.

Out of the cooling line, the birds are weighed again and the grade classification is made right before the whole bird packing distributes the right birds to the right process.

Optimum production flowKnowing the trend 3 hours in advance provides you with obvious advantages regarding production planning and en-ables you to react if corrective actions earlier in the process need to be taken.

Regarding the ProFlex Premium, knowing the midpoint in the weight range makes it possible to adjust to fit the incom-

ing birds (we have a weight variation of -+ 250 g) in order to have the optimum configuration.

With the intelligent ProFlex Premium it has never been eas-ier to combine effective production planning with the best utilisation of raw material.

Accessible management of cut-up process

1

2

3

4

5

6

ClassifEYE® front and back to unveil the tendencies of the flock after rehanging to cooling shackle

520 Transfer Machine from EV line to chilling

Chilling and maturation

Whole bird drop-off for the A-grade birds

7000 birds per hour ProFlex Premium for B-grade birds between 1200 and 1600 g

5000 birds per hour Food Service cut-up for C-grade birds between 1200 and 1600 g

1

2

3

4

1

11

Keeping track of product identification

The ProFlex part singulator is designed to automatically un-load legs or drumsticks directly from the cut-up system and transfer the products to the grader system. If processing 100 legs per minute, the installation of a ProFlex part singulator will reduce manual labour directly by 3-4 operators.

The interesting feature about this transfer unit is that it also transfers the individual product identification to the subse-quent packing process. This opens up for packing mixed pro-ducts on the same grader and calculating the leg yield for every processed bird with B’Logic.

1

2

3

4

Parts are dropped on a conveyor that keeps track of product ID

The conveyor transports the parts and drops them on a singulator

The singulator distributes the parts to the next con-veyor still keeping track of product ID

The singulated parts are transfered to packing without any operators and, still, we keep track of product ID

12

The ProFlex Classic cut-up system* is a very competitive investment as it offers reliable and precise portioning of chickens at line speeds of up to 6000 birds per hour.

ProFlex Classic is designed in a complete frame structure with all cabling pre-wired and as standard delivered as a “plug & play” cut-up system, but it can be configured in a flex line, too.

In general, every cut-up unit is available for ProFlex Classic as well. The bypass and intelligent options require a ProFlex Premium system.

* Please consult “Catalogue of ProFlex units” for more de-tailed information about units.

ProFlex Classic in a frame

13

The ProFlex Fast Food* system is capable of providing the specialised fast-food cuts consisting of wing cuts, keel cut, breast quarters, thighs and drumsticks to cut parts accord-ing to specifications from any common fast-food chain. Due to the modular design of the system, it is easy to add fur-ther cutting units such as Fat Remover and Tail Cutter. In the standard configuration, the system fits into a 40 ft container and is ready to run when unpacked.

Optionally, the line can be equipped with a synchronised food-service conveyor to collect all parts from one bird and transport them to a subsequent packing machine.

The ProFlex Food Service cut-up system can be delivered in the ProFlex Premium or Classic version and the recom-mended capacity is 5000 birds per hour.

* Please consult “Catalogue of ProFlex units” for more de-tailed information about units.

ProFlex Food Service

Drop the cut-up pieces in the flighted conveyor to collect each piece of bird in a single flight

ProFlex Classic ProFlex Premium

14

Simple, strong and durable

Special featuresUnique shackle. Combination of high speed, high accuracy and high yield in a simple, strong and durable construction with height adjustment.

The Premium cut-up shackles have a unique design and of-fer the following features: ■ Slow turning shackle even at high speed (up to 8400

bph) ■ Automatic shackle detection to detect the correct

position ■ Locks to prevent the shackle from swinging ■ Weighing in the shackle

1 2 3 4 5 6

7 8 9 10 11 12

13 14 15 16 17 18

19 20 21

15

How can we cut your birds?

1. Wing tip2. Mid-wing3. Anatomical whole wing4. Silver Dollar Wing5. Drummette6. 2-piece wing - Mid and

drummette7. 2-piece wing - Tip and mid8. Front half with wings9. Front half without wings10. Breast cap11. Split breast cap12. Keel cut13. Vampire cut14. Half chicken15. 6-piece breast16. Saddle17. Saddle without tail18. Leg quarter19. Anatomical leg / whole leg20. Thigh21. Drumstick

Other details and requests

LINCO Food Systems A/SVestermøllevej 9DK-8380 Trige · DenmarkTel.: +45|86 23 14 55Fax: +45|86 23 14 44Mail: linco@baader.com

www.baader.com

This brochure is current as from the publicati on date and supersedes all previous versions. The English version is perceived as the master document and all other versions are subject to incorrect translati on. The indicated limits of the working ranges and performances may vary as a functi on of the proporti on, quality and nutriti onal conditi ons of the birds. In order to achieve an opti mal result, it is recommended to adjust the machine within the working ranges of the bird sizes mainly to be processed. Illustrati ons and dimensions are approximate and not binding. Subject to design changes in the interest of technical progress. Actual scope of supply is specifi ed in our quotati ons and order confi rmati ons and may diff er from descripti ons and photos of this brochure.

Att enti on! For the illustrati on of the technical details the safety devices and protecti on mechanisms are partly not shown in operati ve conditi on. When operati ng the machine, all corresponding devices and instructi ons referring to the safety of the machine are to be uti lised and/or observed. 01-2016 VER03 EN

ProFlex |cut-up systems