ProFlex cut-up systems
ProFlex Premium or ProFlex Classic as standard plug
and play in frame, ProFlex Food Service standard
subsystem with conveyor
Single Bird Processing
Protect your live bird investment
Getting 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
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needs of each of our unique customers.
At BAADER LINCO, we divide our cut-up into 2 systems: ProFlex 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.
AFNR / Shutterstock.com
We act on your needs
Tell 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 counts
We have more than 40 years´ experience in cut-up and more
than 400 systems in different countries all over the globe.
Customising
Let us help you get the customised solution that fits your
set-up - ask us and we will send a specialist to find the system that fits your production - we are flexible and capable
of adapting to your needs and requirements.
Intelligence
Manage the cut-up process by knowing the incoming products and use a combination of weight and quality knowledge to control the cutting process. We know the weight
and quality of every single bird and can direct it to the optimum process.
Solid foundation
The 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.
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Custom-made system to fit in any production
ProFlex cut-up systems offer reliable and precise portioning of chickens and rest on a base of solid frames and highquality 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.
Processing big birds
We have faced improved chicken genetics over the last
half-century and our customers are utilising these improved 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 taking 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.
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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 consumption.
ProFlex Premium cut-up system
ProFlex Food Service
Build your ProFlex cut-up system with intelligent components and use the bypass option for advanced control of
the cut-up process.
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.
The ProFlex Premium system is one of the market’s most advanced 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.
Simple, strong and durable ProFlex Food Service solution
for cutting birds in order to meet the demands from any
fast-food chain.
ProFlex Classic cut-up system
ProFlex 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 Premium
ProFlex Classic
ProFlex Food Service
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Frame line
Intelligence
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Bypass
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Frame line or flex line
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Smooth shackle turn
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Option
Electrical height adjustment
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Option
Supports all types of units
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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
Shackle
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Customise your process with ProFlex Premium
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Tail Cutter
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Wing Tip Cutter
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Mid-joint Cutter
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Whole Wing Cutter
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Breast Pre-Cutter
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Thigh/Drumstick
Cutter w/ bypass
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Leg Releaser
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Leg Releaser
Selective
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Shackle Washer
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Breast Cap Cutter
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Front Half Cutter
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Carcass Cutter
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Leg quarter
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Leg Processor
w/ bypass
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The ProFlex Premium system is a high-speed system capable of handling up to 7000 birds per hour on the standard
12-inch pitch. ProFlex Premium can be arranged to fit existing plant layout.
Anatomical and clean cutting
The 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 distributed to selected drop-off stations for batching, deboning,
filleting or further processing.*
Up to 24 pieces available
The 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 market and region in the world.
Even higher capacity
The 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 Premium 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.
*Please consult “Catalogue of ProFlex units” for more detailed information about units.
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The intelligent ProFlex Premium
We automatically control Single Bird Processing through
the knowledge of weight and quality. Our B’Logic® software 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 Premium. 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.
Bypass is the heart in a balanced production planning
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Balanced production planning
Optimised production depends on three factors: flock characteristics, 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
Accurate single bird weight
Our 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 towards 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 production
Having obtained accurate weight and quality grade of each
bird our new Selective Transfer distributes the birds in accordance with order intake and bird characteristics optimising the utilisation of each bird and order fulfilment.
Stay on track with B’Logic®
Our B’Logic® software presents key production figures captured on the shop floor. If the captured figures deviate too
much from specified target values, the software will give immediate 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
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Accessible management of cut-up process
We can design the optimum workflow to maximise the output 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 Premium 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 cutup 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 flow
Knowing the trend 3 hours in advance provides you with
obvious advantages regarding production planning and enables 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-
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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 easier to combine effective production planning with the best
utilisation of raw material.
1 520 Transfer Machine from EV line to chilling
ClassifEYE® front and back to unveil the tendencies of
2 the flock after rehanging to cooling shackle
3 Chilling and maturation
4 Whole bird drop-off for the A-grade birds
7000 birds per hour ProFlex Premium for B-grade birds
5 between 1200 and 1600 g
5000 birds per hour Food Service cut-up for C-grade
6 birds between 1200 and 1600 g
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Keeping track of product identification
The ProFlex part singulator is designed to automatically unload 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 subsequent packing process. This opens up for packing mixed products on the same grader and calculating the leg yield for
every processed bird with B’Logic.
1 Parts are dropped on a conveyor that keeps track of
product ID
2 The conveyor transports the parts and drops them on
a singulator
3 The singulator distributes the parts to the next conveyor still keeping track of product ID
4 The singulated parts are transfered to packing without
any operators and, still, we keep track of product ID
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ProFlex Classic in a frame
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.
In general, every cut-up unit is available for ProFlex Classic
as well. The bypass and intelligent options require a ProFlex
Premium system.
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.
* Please consult “Catalogue of ProFlex units” for more detailed information about units.
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ProFlex Food Service
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 according to specifications from any common fast-food chain. Due
to the modular design of the system, it is easy to add further 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 recommended capacity is 5000 birds per hour.
* Please consult “Catalogue of ProFlex units” for more detailed information about units.
Drop the cut-up pieces in the flighted conveyor to collect each piece of bird in a single flight
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Simple, strong and durable
ProFlex Classic
Special features
Unique 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 offer 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
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ProFlex Premium
How can we cut your birds?
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Other details and requests
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Wing tip
Mid-wing
Anatomical whole wing
Silver Dollar Wing
Drummette
2-piece wing - Mid and
drummette
2-piece wing - Tip and mid
Front half with wings
Front half without wings
Breast cap
Split breast cap
Keel cut
Vampire cut
Half chicken
6-piece breast
Saddle
Saddle without tail
Leg quarter
Anatomical leg / whole leg
Thigh
Drumstick
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ProFlex |cut-up systems
This brochure is current as from the publication date and supersedes all previous versions. The English
version is perceived as the master document and all other versions are subject to incorrect translation.
The indicated limits of the working ranges and performances may vary as a function of the proportion,
quality and nutritional conditions of the birds. In order to achieve an optimal result, it is recommended
to adjust the machine within the working ranges of the bird sizes mainly to be processed. Illustrations
and dimensions are approximate and not binding. Subject to design changes in the interest of technical
progress. Actual scope of supply is specified in our quotations and order confirmations and may differ
from descriptions and photos of this brochure.
Attention! For the illustration of the technical details the safety devices and protection mechanisms are
partly not shown in operative condition. When operating the machine, all corresponding devices and
instructions referring to the safety of the machine are to be utilised and/or observed.
LINCO Food Systems A/S
Vestermøllevej 9
DK-8380 Trige · Denmark
Tel.: +45|86 23 14 55
Fax: +45|86 23 14 44
Mail: [email protected]
www.baader.com
01-2016 VER03 EN