Poultry Packaging Machines - Types, Prices, and Purchasing

The poultry packaging industry is one of the vital activities in the food sector, aimed at preserving quality and extending the shelf life of products. In the poultry packaging industry, slaughtered chickens are cut, cleaned, and then packaged. During this stage, the packaged products include various parts of the chicken, such as breasts, thighs, wings, and more. Poultry is typically packaged in two forms: fresh and frozen. In fresh packaging, products are placed in nylon bags or plastic containers and are packaged using sealing or stretch wrap machines. These products are then stored in refrigerators to be sold within a short period. In frozen packaging, products are generally placed in plastic bags and then stored at sub-zero temperatures, allowing them to be sold over a longer period.

Types of Poultry and Meat Product Offerings in the Market

Poultry and related products are usually offered in the market in two forms: fresh and frozen.

Fresh Poultry Offerings

Fresh poultry refers to products that are sold within a short time after slaughter and cutting. The advantage of this method is better taste and quality of the poultry. In this method, products are packaged and stored at low temperatures to ensure they can be sold without quality degradation or spoilage.

Frozen Poultry Offerings

In this method, products are rapidly frozen after packaging and then stored at low temperatures (below 0 degrees Celsius). This method provides very long-term storage for the products and can be used as a solution for transporting products to other countries and distant markets. Additionally, freezing the products can significantly extend their shelf life.

Poultry Packaging Methods

Packaging poultry meat and poultry-based products has always been challenging due to their high susceptibility to spoilage and pathogenic microorganisms. To extend shelf life, preservation technologies such as vacuum packaging and modified atmosphere packaging (MAP) are increasingly used for the distribution and sale of poultry and poultry products.

1. Packaging Techniques: There are numerous packaging systems, and the choice of each depends on several factors, including cost, product volume, and the way the product is presented.Recent Packaging Methods Used in the Poultry Industry:
2. Vacuum Packaging: Vacuum packaging involves placing the product in containers (either rigid or flexible) or plastic pouches, from which nearly all air is removed before the final seal is applied. This method is essentially a type of "modified atmosphere" packaging because the normal air is removed from the package.
3. Gas Packaging: Gas packaging can be defined as the replacement of the air in a package with a mixture of gases that differ from normal atmospheric air. This type of packaging is as follows:Modified Atmosphere Packaging (MAP): Refers to a controlled system where gases are added or removed to maintain the desired balance. In this method, the container or external packaging that holds the product is impermeable. The use of Modified Atmosphere Packaging for meat and meat products has significantly increased in recent years. MAP foods are increasingly available as food manufacturers have sought to meet consumer demand for fresh refrigerated foods with extended shelf life without using chemical preservatives. The basis of Modified Atmosphere Packaging is to replace the air inside the package with a fixed mixture of gases, and once the gases are introduced, no further control over the gas composition is applied, and the composition inevitably changes.The spoilage of raw poultry and other birds is primarily due to microbial growth, particularly the growth of Pseudomonas species and Acromobacter species. These aerobic spoilage bacteria are effectively controlled by incorporating CO2 in Modified Atmosphere Packaging (MAP).To significantly extend the shelf life of raw poultry and other birds, CO2 levels greater than 20% are required. For retail packaging of chicken and poultry using the MAP method, the CO2 ratio in the gas mixture should not exceed 40% as it may cause the packages to collapse and excessive droplet formation. If higher CO2 levels are used, the gas-to-product ratio should be increased. In cases where visible package damage is not an issue (e.g., bulk or primary bags), the use of 100% CO2 is recommended. For MAP packaging for the final consumer, a mixture of 30% CO2 and 70% N2 is often recommended, with nitrogen serving as an inert filler gas.The achievable shelf life for poultry packaged with MAP depends on the species, fat content, initial microbial load, gas mixture, and storage temperature. Potential food poisoning hazards can be minimized by maintaining the recommended cold temperatures, adhering to hygiene practices, proper handling, and ensuring adequate cooking before consumption.
4. Active PackagingActive packaging is a modern method consisting of various techniques where the packaging actively interacts with the food products to enhance shelf life, maintain quality, and ensure safety in conjunction with the internal atmosphere. Active packaging utilizes a range of innovative techniques to interact with food products and enhance their shelf life, quality, and safety. Some of the potential techniques include.By employing these techniques, active packaging can significantly improve the preservation and quality of fresh food products, ensuring they remain safe and appealing to consumers.
5. Active Packaging AbsorbersActive packaging absorbers are materials designed to absorb, remove, and eliminate substances such as oxygen, ethylene, moisture, or stains from within food packaging. The components of active packaging can significantly affect the shelf life and organoleptic properties of food. Most commercial oxygen absorbers are based on iron powder, which reacts with oxygen to form iron oxide. Non-metallic and organometallic compounds have also been developed. These absorbers can be particularly beneficial for certain products. Adding an absorber inside the package, along with a physical protective coating, can maintain oxygen levels close to 0.01% within the package. This helps in preserving the quality and extending the shelf life of the product.Antimicrobial Agents : By directly incorporating antimicrobial agents into packaging films, the packaging material can serve as a source for releasing preservatives or antimicrobial substances, or even prevent the growth of microorganisms. This form of packaging is one of the most promising types of active packaging. Among the various applications of active packaging, the integration and/or slow release of antimicrobial agents have garnered significant attention as methods to extend the lag phase of bacterial growth, reduce the growth rate of microorganisms, prolong shelf life, and maintain food safety.The general concept of antimicrobial packaging involves the controlled release of antimicrobial compounds into the food through diffusion or partitioning. This approach not only allows for the initial inhibition of undesirable microorganisms but also ensures sustained antimicrobial activity over time.
6. Active Packaging Dispersers : This category of active packaging contains or generates substances that penetrate the packaging atmosphere or the food itself to achieve a technological effect. Examples include food additives and flavor enhancers. In these cases, the consumer ingests the incorporated components along with the food.

Poultry Processing and Packaging Line Operation

The production and packaging line for poultry meat typically involves several stages, detailed as follows: Poultry such as chickens, turkeys, ducks, partridges, quails, etc., are raised to an appropriate weight and checked for disease before being transported to the slaughterhouse. After humane slaughter, a technical hygiene inspection is conducted.Carcasses are transported to the factory under suitable conditions.

• Inspection on the Production Line : Carcasses are transferred to the production line and inspected again for external attributes like skin color, meat color, fat, bruising, etc.Only carcasses meeting quality standards proceed to the preparation stage.
• Preparation : Raw materials are washed to remove any contamination, dirt, or bacteria.
• Skinning :The skin is separated from the meat.
• Cutting and Portioning : The meat is cut to the required sizes and, if necessary, deboned.
• Packaging: Products are packaged in the desired quantities using automatic packaging machines or manually by workers. Packaging options include vacuum packaging, MAP (Modified Atmosphere Packaging), or active packaging to ensure ease of storage, transport, and sale.
• Freezing : For frozen products, the meat is subjected to very low temperatures to freeze and extend its shelf life.This process reduces the growth of bacteria and microorganisms, ensuring consumer safety.Frozen products are stored in cold storage until they are shipped to stores or other customers.For fresh products, the freezing step is omitted. Fresh products are packaged using vacuum sealers with gas injection to maintain freshness and extend shelf life, allowing enough time for sale in retail outlets.
• Printing and Labeling :Packaged products are labeled with necessary information such as product name, expiration date, storage instructions, etc.

Quality Control, At each stage, the quality of materials and products is inspected to ensure they meet the highest standards for production and delivery to customers.

Types of Chicken and Meat Packaging Machines

Here we review optimized packaging methods for meat products using various packaging machines:

Automatic Tray Sealer Packaging Machine

The packaging process for poultry and meat products using this machine involves the following steps: Tray Placement and Sterilization : Pre-made trays are placed either automatically (using an automatic tray placer) or manually on the machine.The empty trays pass through a UV tunnel for sterilization, which significantly reduces the microbial load on the trays, directly impacting the product's shelf life. Product Placement and Sealing : The products are manually placed into the trays. The filled trays are then guided into the machine’s mold where they undergo vacuum sealing. During this stage, a film is sealed over the tray, completing the packaging. Labeling : After sealing, the packaged trays can be directed to a labeling station. Labels with the date and other relevant information are applied to the packages.

For more information, you can visit the automatic tray sealer packaging machine page.

semi-automatic tray sealer packaging machine

The semi-automatic tray sealer packaging machine is used for packaging poultry in small to medium scales. This machine is also used in stores and small businesses. To operate the machine, after placing the filled containers onto the mold, the table needs to be rotated 180 degrees by the operator. Then, by pressing the buttons, the operator issues the packaging command.

For more information, you can visit the semi-automatic tray sealer packaging machine page.

Vacuum Chamber Packaging Machine

The vacuum chamber packaging machine, also known as the cabinet vacuum machine (available in single and double cabinets), is used for packaging various food products, including poultry, in plastic bags. This machine can utilize various types of bags with different materials and prints. Depending on the desired packaging type, the machine can perform a full vacuum, making the bag or plastic cover adhere tightly to the product, or gas injection can be done instead of vacuuming. This process helps increase the shelf life of the fresh product.

For more information, you can visit the Vacuum Chamber Packaging Machine.

Thermoforming Packaging Machine

The thermoforming packaging machine by Packen Company is used for packaging various food products, including poultry. This machine is widely used by many factories for packaging meat products on a large scale. With this machine, you can automatically package products in either flexible or rigid film. Using this machine, it is possible to produce containers of different sizes on the production line, automatically load them, and package them using various methods. If you need production capacity at your desired levels, you can contact us for guidance on building a machine with your specific capacity requirements. Additionally, automatic fillers (multi-head weighers) are used in some packaging lines to achieve a higher degree of automation. However, in many cases, the weighing process is performed manually by operators, and products are loaded into containers using both automated and manual methods. It is worth noting that Packen Company’s machines are capable of packaging not only poultry products but also the following items:

• Various dried fruits
• Various ready-to-eat cold foods
• Pickles (such as cucumbers and olives) and other preserved foods
• Various meat and protein products
• Vegetables, fruits, and salads
• Packaging of some dairy products, such as cheese
• Bread and pastries
• Medical and hygiene equipment

For more information, you can visit the thermoforming packaging machine page.

Packaging Containers for Poultry Products

The containers used for packaging can be designed and manufactured in various shapes and materials, including:

• C-PET
• A-PET
• R-PET Polypropylene
• Styrene
• Smooth Wall Foil Aluminium

Attractive container shapes can enhance the appearance of the packaging and positively impact sales. Packen Company, with its expertise in packaging machinery, can provide customers with custom molds for producing these containers. Therefore, customers who need a uniquely shaped container for packaging their meat products, distinct from standard containers available in the market, can submit their design. At Packen, we will use a 3D printer to create a prototype. After your approval, we will manufacture the mold and produce the container in your desired quantity. Given our expertise in packaging various food products and medical equipment, we can provide you with the necessary information on selecting the right film and container type for your product. You can consult with Packen to choose the best container for packaging poultry products and acquire it at the best price.

Types of Films Used in Packaging

The types of films used in packaging include standard 2-layer films, multi-layer barrier films, skin pack films, breathable films, anti-fog films, and more. Packen Company provides containers made from various materials suitable for both food and pharmaceutical applications.

Important Considerations When Buying a Poultry Packaging Machine

Purchasing a poultry packaging machine is a crucial step in the production and distribution of poultry products. Proper packaging enhances product quality, shelf life, and added value. Here are some key points to consider when buying a poultry packaging machine: Your Needs: The first thing to consider is your specific needs. Assess the types of products you plan to package in the future and ensure the machine you choose can handle them effectively. Type of Machine: Poultry packaging machines can be manual, semi-automatic, or fully automatic. Determine which type aligns best with your business needs. Fully automatic machines generally offer higher levels of automation, which increases speed and accuracy in the packaging process. Machine Speed: The speed of the packaging machine should match your production volume. This depends on factors such as package size, type, and your production line's capacity. After-Sales Service: After-sales service is essential for ensuring proper use of the machine and resolving any issues that may arise. This includes repairs, part replacements, and routine maintenance. Ensure the manufacturer provides responsive customer support. Brand and Manufacturer: Choosing a reputable brand and manufacturer is beneficial as they often invest in research and development, focusing on quality and performance. This ensures that the machine is built with the latest technologies and high-quality materials. Health and Safety Standards: Adherence to performance and quality standards can help you select a machine that meets high safety and efficiency criteria. For example, CE certification indicates compliance with European Union regulations. Other standards like ISO 9001 can also ensure high quality and performance. Price: Compare the price of the machine with similar models to make an informed decision based on cost and quality. Opt for a reliable and high-quality machine, even if it comes at a higher price. Also, consider the cost of spare parts and after-sales services. Ease of Use and Efficiency: The machine's ease of use can significantly impact its efficiency and maintenance costs. A user-friendly machine requires less training, and operators can use it effectively with minimal specialized knowledge. Additionally, easy cleaning and maintenance reduce the need for extensive service. Machine Placement: Before purchasing, consider the machine's placement within your production area to ensure it fits well with the production line layout and other requirements.

Machine Purchase Price

The price of a poultry packaging machine depends on factors such as the type and size of the machine, its quality, and brand. Additionally, the manufacturer and the method of purchase can also impact the price. When purchasing a poultry packaging machine, it's essential to first assess your needs and determine the type and size of the machine required. By comparing prices available in the market and reviewing the features of different machines, you can make a more informed decision. Keep in mind that the purchase cost of the machine is just one of the expenses. Costs such as maintenance, repairs, spare parts, and energy consumption should also be considered. Therefore, it is advisable to calculate all related costs before making a purchase and choose a machine that fits your budget and requirements. If you have a limited budget, buying the machine on installments can be a suitable option, provided it is done through a reputable and reliable supplier. This way, you can acquire the machine with an initial down payment and pay the remaining amount in monthly installments. For more information, you can contact our experts at Packen.