49-Fabricando Made in Spain - pollos corral

The Journey of Free-Range Chicken Production

Introduction to Free-Range Chicken

• The consumption of chicken has been a part of human diets for centuries, with free-range chickens being integral to various recipes and diets in the region.

• The focus is on understanding the production process of free-range chicken, emphasizing healthy eating and quality care.

Breeding Process

• The cooperative's mission involves maintaining breeding hens that produce fertilized eggs through interaction with roosters.

• Hens lay approximately one egg daily; only some are fertilized, while non-fertilized eggs are used for human consumption.

Incubation and Hatching

• There are two types of hens: laying hens (for consumption) and breeding hens (for producing chicks).

• In the incubation facility, conditions mimic those provided by a mother hen to ensure successful hatching.

Conditions for Incubation

• Eggs are incubated at 38 degrees Celsius with controlled humidity and ventilation to optimize hatching success.

• After 18 days in the incubator, eggs are prepared for hatching, with tracking information about their origin and care.

Observing Newborn Chicks

• Newly hatched chicks have different appearances based on their breeds; they require specific conditions post-hatch.

• Chicks can take varying amounts of time to hatch; some may be born earlier than others depending on vitality.

Post-Hatch Care

• Newly hatched chicks rely on nutrients from the yolk sac initially; they need careful handling during this delicate stage.

• Once separated by sex, chicks will be sent to farms for further growth.

Techniques for Sexing Chicks

Traditional Methods of Differentiation

• The chick's anatomy allows experts to differentiate between males and females, particularly through the cloaca, a shared opening for the urinary and reproductive systems.

• Another method involves examining the wing feather arrangement; male chicks have equal or longer primary feathers compared to secondary ones, while female chicks do not.

Gender Identification Skills

• It is noted that women often excel in identifying chick genders due to their keen observational skills, with some capable of processing up to 2,700 chicks efficiently.

• Female chicks are prioritized for raising while males are sent off separately; this division is crucial for managing production lines effectively.

Chick Growth and Egg Production

Timeline of Chick Development

• Chicks reach an ideal weight and size within three months but do not start laying eggs until they are five or six months old.

• The yellowish hue of the plumage in chicks is attributed to their diet, primarily consisting of corn.

Processing Timeline

• At three months old, chickens are ready for processing. A humane slaughter process ensures minimal suffering before cleaning begins.

Chicken Processing Efficiency

Monitoring Production Rates

• A marker tracks the number of chickens processed per hour on a conveyor system designed to handle 560 hooks at a time.

• The facility ranks as one of Europe's top chicken consumers, necessitating highly productive processes to meet market demands.

Temperature Control in Processing

• After slaughtering, chickens must be cooled from 36 degrees Celsius down to 2 degrees Celsius using hyperventilation techniques.

Packaging and Distribution

Classification Process

• During packaging, chickens are sorted by weight; preferences vary regionally with larger birds favored in southern areas versus medium-sized birds in northern regions.

Automation in Packaging

• Automated systems ensure precise weight classification during packaging; blue hooks indicate where birds drop based on their calibrated weights.

Traceability and Quality Control

Ensuring Product Integrity

• Each day approximately 20,000 free-range chickens are processed with robust tracking systems ensuring traceability from farm to consumer.

Incubation Process Overview

Proceso de Clasificación y Procesamiento de Animales

Clasificación y Transporte

• Los animales son clasificados por sexo en una máquina redonda antes de ser transportados a la granja.

• En la granja, los animales crecen durante tres meses hasta alcanzar el peso y tamaño adecuados para el procesamiento.

Sacrificio y Limpieza

• Una vez que llegan a las plantas, los animales son sacrificados y limpiados internamente.

• Después del proceso de limpieza, se refrigeran para mantener la cadena de frío durante todo el proceso.

Clasificación Final