Heat exchangers for efficient poultry processing

Two Contherm scraped surface heat exchangers have boosted productivity and profitability at a leading UK processor of poultry meat, Ken Read and Son of Market Deeping, Cambridge

One of the UK's leading processors of poultry meat, Ken Read and Son of Market Deeping, Cambs, has increased quality and improved both its productivity and profitability since the installation of two Contherm Scraped Surface Heat Exchangers from Alfa Laval.

Ken Read and Son was established in 1978 and has rapidly established a reputation for quality products and created substantial markets both in the UK and abroad with up to 90% of its product earmarked for export markets.

A major factor in the company success has been the adoption of the latest and best technology whenever it becomes available.

This has enabled the company to grow steadily and increase capacity while at the same time limiting costs, particularly in terms of manual labour.

The Ken Read principal product is chicken and turkey meat, which is mechanically de-boned and then frozen in blocks ready for use in fast and processed foods.

Their Market Deeping factory, which they moved into ten years ago, has been purpose-equipped to make the process as fast and efficient as possible.

The latest stage in this drive for efficiency saw the installation of the Contherm SSHEs at the end of 2004.

These two units, along with the ancillary tubing and two Alfa Laval SRU pumps, were supplied and installed by S and W Group, one of the major Alfa Laval process partners serving the food industry.

The very act of de-boning and processing chicken and turkey carcasses adds energy in the form of heat.

In fact, by the end of the process the temperature of the product can be as high as 100C.

This has to be reduced gently - but quickly - to less than +40C to comply with the latest legislation.

Prior to the installation of the two Contherms, a bank of plate freezers was used for this purpose.

The processed meat was pumped into individual compartments in each tray to form 10 kilo slabs and was frozen down to around -15C ready for shipment.

Since its temperature had to be reduced from a starting point of around +100C, this was a lengthy process.

By contrast, the two Contherm exchangers enable the process to run much faster having taken 6C out of the product temperature before it enters the freezers.

Product enters the heat exchangers at +100C and exits at somewhere between +3 to +40C.

The cooling medium is ammonia, which circulates through a cooling jacket at -7C.

Each Contherm incorporates scrapers which continuously scrape the interior surfaces of the exchanger, preventing any risk of fouling and ensuring that heat is transferred uniformly.

From the Contherms, the chilled product is transferred to a buffer vessel before entering a newly installed vertical bagger where it is packed in individual 10 kilo portions.

The final stop is two new fully automatic plate freezers which reduce the temperature to the -15C required for shipment.

The Contherm installation saves Ken Read a significant amount of time because each freezing cycle takes approximately 15 minutes less due to the reduced inlet temperature.

Taken with the improvement in temperature control and product quality and the fact that the process is now continuous, the system has very quickly justified the company decision to install it.

In fact, according to Ian Hart, Ken Read Operations Director, "The Contherm system represents a significant step up for us both in terms of technology and our efficiency.

In that respect, it has been a key element in our re-equipment programme, which is still continuing.

in the immediate future, we intend to install a new robotic palletiser and stretch wrapper and, probably at a later date, another double Contherm system to complement the existing one.".

Back to top