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By Fabio Gualtieri, Pelbo SPA, Italy
To break or not to break eggs? This is the question many packing stations face when dealing with rejected eggs from the sorting operation, especially when the egg market is down. Furthermore, the volatility of prices of these eggs and the limited market outlets for them makes this matter complicated to deal with.The fragile nature of the eggs generates sanitation issues in the equipment that is used to handle them. Also there is an increased risk of cross contamination. And eggs broken during tray and pallet handling turn into potential sources of food for vermin and insects. Moreover, broken eggs generate “stuck eggs” and promote mould which translates to losses for the processing plant. This plant eventually complains and demands a better price, or a discount or returns the eggs to the packaging station.
Integrated solutions
Yield losses during storage, transport to the breaking plant and loading to breaking equipment have been estimated between 4% and 7%. When combining this loss with the down-time generated at the breaking plant, packaging material waste, and the environmental impact due to additional cleaning compounds and water, it can reach staggering numbers.
Yield losses during storage, transport to the breaking plant and loading to breaking equipment have been estimated between 4% and 7%. When combining this loss with the down-time generated at the breaking plant, packaging material waste, and the environmental impact due to additional cleaning compounds and water, it can reach staggering numbers.
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| Proper mixing is an important stage in the processing procedure. |
Completely integrated solutions incorporating all the steps necessary to produce high-quality egg products are pre-assembled into stainless steel frames, ready to operate within a few days after arrival at the plant.
Packing stations can install these systems in a small room adjacent to the grading operation, with a belt or conveyor directly from the grading machine to the egg breaker. The egg breaker receives and breaks the eggs and the egg product immediately enters a blending tank to create a homogeneous mix. From the tank, the products are filtered and immediately pasteurised and packaged. The amount of time that it takes an egg from the time it is broken to being pasteurised and packaged is less than 20 minutes.
Minimum handling
The liquid egg products can be packaged into a wide range of packing materials such as bag-in-box, bottles, pallecon boxes, pails or for a bit more money, gable-top type packages. Because the eggs are fresh and go through minimum handling, the system allows for production of high-value extended shelf life egg products, or minimally treated liquid products that can be sold to other processing operations.
The liquid egg products can be packaged into a wide range of packing materials such as bag-in-box, bottles, pallecon boxes, pails or for a bit more money, gable-top type packages. Because the eggs are fresh and go through minimum handling, the system allows for production of high-value extended shelf life egg products, or minimally treated liquid products that can be sold to other processing operations.
This may even allow packing stations to divert eggs seasonally to the breaking operation as the egg market fluctuates, as well as to divert difficult to grade eggs such as eggs from old hens. The systems are completely integrated which means that not only the processing equipment is included, but that all support equipment (heating/cooling), cleaning equipment and controls for a quick, easy and flawless installation.
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Source: World Poultry, Vol. 27, No. 4, 2011
