Maple Lodge Farms Ltd®, Canada's largest independently owned poultry processor, selected Heat and Control® to automate the spicing of their whole birds. After preliminary testing to refine the process, a Spray Dynamics® system was installed and operational in July 2018 with results immediately and continuing to surpass initial projections.
In 2017, Maple Lodge Farms developed an aggressive strategy to grow annual revenue and market share over the next several years. To execute the plan and to meet expected new demand, they needed to expand their capacity by automating the manual process of spicing whole birds. Although the private Brampton, Canada-based company offers a variety of chicken products, including sliced deli, deli roasts, wieners, bacon, and frozen products, spiced birds were an integral component of the growth plan so that product line became their focus.
Spiced Whole Birds Maple Lodge Director of Continuous Improvement, Kevin Shaw, and a team developed a characteristic selection matrix (CSM), as well as utilized a variety of other tools, to determine their key criteria and objectives and selected several companies to submit their proposals. They selected Heat and Control because of their legacy of innovation, complete solution offering, and commitment to support. Maple Lodge Farms added the Spray Dynamics' whole bird chicken seasoning system that included a USDA polished broken-in flight coating drum (with tube on diamond construction), Unispense III high volume dry ingredient dispenser, a Scarf Plate dry ingredient Feeder and PLC Controls and Information system for recipe management.
The ability to reduce spice waste was a key advantage, and because of the dedicated support after installation and the success of equipment used in the improved process, Maple Lodge is looking again to Heat and Control for their next phase of growth.
"At the completion of the project in August, all objectives and critical criteria have been met and the results have overwhelmingly surpassed all expectations. We have overachieved in the spiced bird coverage and pick-up, a significant reduction in waste and through-put has increased dramatically."
Kevin Shaw, Director of Continuous Improvement
Heat and Control manufactures and supplies complete line solutions for the snack industry. Along with their partners Ishida and CEIA, Heat and Control can provide solutions of one machine or a complete line. From processing, seasoning and coating application and conveying, to weighing, bagmaking, packaging, metal detection, X-ray inspection, and checkweighing.
With experience and expertise since 1950, Heat and Control can assist with process development, custom engineering, leading edge technology, and equipment for all types of snack products. A full-service offering includes pre- and post-sale technical support, including applications assistance, engineering, installation, parts, service, and training.