Ghana has fast-growing domestic demand for consistent, hygienic chilled chicken products. This plant is built to meet local food authority hygiene requirements, follow halal slaughter protocols, and suit West African operating conditions including unstable power supply and high ambient temperature.

[IMAGE: 项目流程信息图，2000BPH 产能、全流程概览]

Client Background

The customer owns breeder farms and grow-out sites across Ghana. They planned this new processing facility to supply fresh chicken for urban markets and regional retail chains. Their original operation depended on small-scale manual slaughter, with clear pain points:

1. Manual bird unloading and shackling caused high bruising and DOA, product quality unstable.
2. Manual evisceration and offal sorting could not maintain consistent hygiene for retail distribution.
3. Limited chilling capacity struggled under Ghana’s hot climate, shortening shelf life.
4. They wanted a single turnkey supplier to deliver a compact, reliable complete line, easy to run and maintain with local labor.

After comparison, they selected our turnkey solution. We designed the whole plant compactly for medium capacity, with robust equipment suitable for West African site conditions and straightforward operation & maintenance.

[IMAGE: 原有手工屠宰场景参考图]

Our Solution: 2,000 BPH Compact Turnkey Processing Line

We adopted a continuous overhead shackle rail layout, with clear separation of dirty and clean zones. All equipment uses food-grade 304 stainless steel and supports CIP cleaning. The whole system is optimized for 2000BPH steady running, with power stabilisation and enhanced chilling capacity adapted for local hot weather.

1. Live bird receiving & crate unloading section

Front-end unloading station built for medium-volume continuous operation:

• Crate depalletizing and gentle bird release system to reduce stress and bruising
• Empty crate washing, sanitising and stacking for recycling back to farms
• Live bird shackling station feeding the main overhead processing line

[IMAGE: 卸笼工位全景]

2. Slaughter, scalding and defeathering section

• Stunning unit adjustable to match local halal slaughter requirements
• Extended bleeding station to guarantee sufficient bleed-out time
• Precision temperature controlled scald tank, stable feather removal without skin damage
• Combined multi-stage plucking unit, reliable for continuous 2000BPH production
• Automatic head and feet separation station

3. Carcass inspection, washing and offal fine treatment zone

Carcasses travel along the overhead rail for veterinary inspection. After primary evisceration, viscera go into the dedicated offal processing zone. This area follows standardized hygienic workflows for sorting, cleaning, trimming and quality screening of hearts, livers and gizzards. Qualified offal is collected for sale, while rejected materials are sent to by-product handling. One-way flow design prevents cross-contamination between carcasses and offal.

[IMAGE: 内脏处理车间全景，不特写单机]

4. Chilling system

Enhanced counter-flow immersion chilling system customized for high ambient temperature:

• Pre-chiller for fast initial heat reduction
• Main chiller to bring carcass temperature down below 4℃
• Air drying tunnel to remove surface moisture before finishing and packing

5. Portion finishing workshop

After chilling and drying, carcasses move to the finishing area for standardized cutting, trimming and QC. Operators can switch production flexibly according to market demand: whole carcass packing, or cut into leg quarters, wings and breast portions. Quality control staff remove defects and bone fragments. Finished products go directly to packaging and cold storage.

[IMAGE: 分割整理车间全景，侧重动线]

6. By-product recovery

Feathers, blood and other by-products are collected for further processing, improving overall project profit.

Installation, Commissioning & Training

Our engineering team completed the turnkey delivery on site:

• Install overhead rail, unloading, scalding, plucking, chilling and conveying systems
• Complete electrical, water and refrigeration integration, with power stabilisation setup
• Conduct dry testing and gradual speed ramp-up until stable 2000BPH continuous operation
• Train local operators on line operation, CIP cleaning, temperature logging and routine maintenance
• Verify the full production workflow to ensure smooth coordination between all processing zones
• Support local food hygiene inspection and halal compliance documentation

We supplied English operation manuals and long-term remote technical support, plus spare parts package for local maintenance.

[IMAGE: 工程师现场培训当地操作人员]

Project Results

After commissioning, the turnkey plant reached all targets:

• Stable continuous production of 2,000 birds per hour, meeting local retail and regional supply orders
• Automatic unloading reduced bruising and DOA rate greatly
• Zone separation and standardized workflows satisfy local food safety and halal requirements
• The compact layout fits the customer’s land and building plan perfectly
• Simplified operation and maintenance suit local technicians
• Chilling performance matches Ghana’s high-temperature environment, extending shelf life of fresh chicken

“We needed a dependable turnkey partner to build our medium-scale poultry plant. The complete line they delivered is easy to run and fits our local market requirements perfectly.” — Project Manager, Ghana Poultry Operator

[IMAGE: 成品冷藏鸡肉产品]

Suitable Customer Groups for This 2,000 BPH Turnkey Solution

This medium-capacity turnkey poultry plant is ideal for:

• Local poultry investors in West Africa building fresh chicken supply bases
• Operators upgrading from manual slaughter to standardized semi-industrial processing
• Buyers looking for compact turnkey lines covering unloading, slaughter, chilling, offal and portion processing
• Projects requiring halal-compliant, easy-maintenance poultry slaughter equipment for tropical climates

We also provide turnkey lines from 500 BPH up to 15,000 BPH for different market scales.