Optimizing your process
We focus on specific situations and have a broad view on the whole process.
The Hurdle Concept
Creating hurdles improves hygiene
The main principle of the hurdle concept is to prevent dirt and bacteria from passing to the next processing step. In poultry processing, for example, loose feathers attached to skin or shackles must be prevented from entering the evisceration process.
In almost all cases, a hurdle consists of a washing step: a nozzle on the machine or within a cabinet dedicated to this function. The more effectively dirt and bacteria are removed, the less likely they are to pass further into the process and ultimately end up in or on the final products.
Hurdles in a typical poultry processing production line:
Undine® takes it to the next level
The so-called hurdle concept has been a part of poultry processing for many years. Scientists have conducted extensive research on the hurdle concept, and the poultry industry has implemented many of their findings to improve hygiene. In fact, most process implementations in the industry can be understood in the context of the hurdle approach.
However, many poultry processing plants struggle with water consumption and water pressure, which leads to a less hygienic process and end product. Our Undine® technology takes the hurdle approach to the next level. Undine® makes it possible to significantly improve the overall hygiene level of poultry processing plants. Existing hurdles can not only be made more effective, but additional hurdles that were previously unfeasible can also be created, thanks to the significant water savings achieved with Undine®.
Separating process steps based on hygiene
The hurdle concept involves separating processing steps based on hygiene. When products are rehung onto another line with a higher hygiene status, they must be as clean as possible. Therefore, processing plants are divided into different hygiene zones, such as the slaughter and evisceration departments. Moreover, machine manufacturers have implemented provisions (hurdles) to ensure hygiene within each line.
Water pressure and concumption challenges
The results of all provisions and cleaning steps depend heavily on water pressure. Some plant managers struggle to achieve the correct water pressure due to insufficient water supply, while others must limit water pressure to remain within water usage restrictions. Both cases result in a less hygienic process and end product. Often, there is a trade-off between hygiene and water consumption. While a processor may still meet legal requirements, this is often not enough to satisfy the industry’s stricter quality standards, which are designed to create added value.
Undine® solves this dilemma by simultaneously reducing water consumption and improving hygiene.
How Undine® works
Our Undine® technology enormously boosts the cleaning effect of water. Water and air are mixed under pressure in Undine®’s mixing chambers. This results in highly effective cleaning, improved hygiene, and extremely low water usage. It takes the hurdle approach to the next level. In some cases, it even becomes possible to remove specific bacteria, such as Salmonella and Enterobacteria.
Undine® enables additional hurdles
By saving water, it becomes feasible to install extra washers, thereby creating additional hurdles, all while staying within acceptable water usage limits. In fact, even with the extra washers installed, Undine® still achieves significant water savings.
The benefits of a washer after the cropper
It is highly uncommon for poultry processing plants to install washers behind the cropper. Nevertheless, we frequently install an additional washer in this position, which has a profound effect on removing Salmonella bacteria from poultry. This results in cleaner birds, fewer rejections, and better hygiene overall.
Our cleaning solutions for poultry processing plants
Undine® makes it possible to significantly improve the overall hygiene level of a poultry processing plant. Existing hurdles are made more effective, and additional hurdles that were not feasible before, can be created thanks to the huge water savings.
Our solutions for creating hurdles in poultry processing
- Before scalding (new)
- On pluckers (improved)
- After plucking (improved)
- Venter (new)
- Opener (new)
- Eviscerator (improved)
- Cropper (new)
- Neck breaker (new)
- Final inspection machine (new/improved)
- I/O washer (improved)
An overview of the process from entry to departure can be found here.
We know which solutions are right for you
Would you also like to improve hygiene and save on water, energy and personnel costs? Please feel free to contact our experts. They are happy to provide personal advice. Which solutions suit you best, depends on your specific plant configuration and products.
Undine® - how does it work?
The Undine® technology is, in essence, simple—just as any good technology should be. A simple technique features a straightforward design, allowing for easy installation and low maintenance.
Our secret lies in breaking up the water flow into microdroplets and accelerating them to much higher speeds. These high-speed microdroplets exert more force on contaminants than a traditional water jet alone can.
We have conducted studies to explain the physics behind this process and to demonstrate why Undine® penetrates surfaces more effectively than a standard water jet—without causing surface damage. This is a critical factor when cleaning poultry.
The Undine® unit mixes water with pressurized air for ultimate cleaning performance.
