PROCESSED CHICKEN MEAT
PRODUCTION TECHNOLOGY
We produce our high quality products in our processed food facility under sanitary conditions in order to present healthy, reliable and delicious products to our consumers and clients. Visitors can observe the cleanliness of each of our production steps by observing the operation from the observation halls. Furthermore, we record every operation in our facility using recording and observation systems. We run all of our production plans, production, storage, delivery, sales and accounting types of activities using SAP system relative to each other.
In brief, the steps of our production procedures include acceptance of the raw material, preparation of the raw material, filling and processing procedures, packing or bagging after cooking and cooling down processes, and finally, acceptance of the products at depots and delivery of the products to customers using distribution points and vendors. Certaiinly, this production is very detailed. If we try to expalin our production adventure briefly...
Experimental productions are carried out in our AR-GE laboratory, which is a pilot facility, before mass production starts. Our laboratory is used to control the products accoring to microbilogical and chemical analysis and every product is put into mass production after it has undergone testing on our main production line.
Our facility is divided into two sections: production section and packaging section. The employees are prohibited from passing from production area to packing area, and employees of each section wear different outfits. The separation of these areas and the separation of the employees of these areas by using different outfits is a precautionary step to prevent contamination. This divided section is also divided into two internal production sections. In our processed food production line, products such as suasage, salami and burger meat are produced from 100% chicken meat and products such as cordon blue, schnitzel, nuggets, crispy burgers as wells as kebab, patty, and sliced meat are produced in the other line. Packed croquets produced specifically for children are packed in packages that feature Tom and Jerry pictures. Also, sausages produced from chicken meat are packed in boxes that feature Tom and Jerry pictures and they are presented to the market in this form in order to attract the interest of children, whereby they can be provided with a nutritious meal.
Every step of the sanitary production process in our facility is controlled. Every step, starting from the slaughterhouses up to the point that the chicken meat reaches our facility is controlled by laboratory analyses. The chicken meat that is recieved by our facility once again undergoes an acceptance analysis. All materials are then delivered to our depots in accordance to proper storage conditions. Meat storage, other raw material depot for materials that are to be kept in cold storages, and packing material depot are all separated and kept apart from each other.
Materials required for every day production are dispatched to production line employees by storage room employees. Controlled delivery and acceptance is also implemented in this step and all these controls are systematically recorded in internal control documents.
Chicken meats that are spiced with spices exclusive to CP, after the completion of the raw material process, are then entered into the shaping step. Our spiced products, patties and kebabs are directed towards forming lines, while products such as sausage and salami are directed towards filling lines. To produce a product with high quality, structural and sanitary controls, as well as plating, weight and temperature controls, are carried out. All controls that are implemented according to food legislations are recorded in the internal documentation system.
The shaping and filling processes are followed by cooking process. Product structure, internal temperature, shape and color are controlled and recorded in this step. After the cooking process is completed the cooling process starts.
After the cooling process is determined according to the particular products and new varieties, the products then enter the packing process, which is considered the most risk-filled process. Product structure, internal temperature, shape and color are controlled and recorded in this step
The products that exit the production line continue their way to the packing process. The products are then packed after they are weighed in accordance to food legislations and internal audit criteria. These products are passed through a metal detection machine and are delivered to the bagging section. The packing section and bagging section are seperated from each other. The packed products are once again weighed automatically after passing through the metal detection section, and the packages that weigh less than the standard weights are separated. Samples taken from each batch before and after packing are subject to physical, chemical and micro biological analyses, and the products are not dispatched until the test results are obtained. In addition to these analyses, an organoleptic analysis of the products are carried out in the AR-GE laboratory.
The products bagged in the bagging section are then moved to freezing or cold storage rooms, depending on the product. A shelfing system exists in our well equipped storage rooms, and all placements and dispatches are carried out according to FIFO principals.
Our deliveries are carried out in frigorific vehicles, ensuring that the cold chain is not interrupted. Products are delivered from our facililities to CP sales points, vendors and distribution points, and throughout the delivery process, their temperature and moisture are controlled using automatic equipment .
