JBT Marel FHF FlexControl Optimises Front Half Deboning at Boscher Volailles

In high-volume poultry processing, particularly in operations focused on front half deboning, maximizing yield per bird while maintaining line stability is a critical performance factor. At Boscher Volailles, five FHF FlexControl lines from JBT Marel now process up to 730,000 chickens per week, supporting higher recovery rates and improved operational efficiency.

The installation strengthens Boscher Volailles’ long-standing strategy of deboning front halves instead of breast caps to enable systematic back meat recovery — a key contributor to yield optimization in industrial poultry processing.

Increasing Yield Through Precise Weight Allocation
Boscher Volailles processes male birds with an average live weight of 3.3 kg. Uniformity allows the use of standardized processing recipes. However, weight variations between batches require flexible line configuration.

Using SmartWeigher allocation, birds are automatically distributed across four deboning lines according to weight. This approach allows each FHF FlexControl line to operate within optimized process parameters, improving consistency and reducing trimming losses.

With weekly throughput approaching 730,000 birds, even minor yield improvements per unit translate into measurable financial gains over time.

Remote Adjustments Without Line Stops
One of the main operational advantages of the FHF FlexControl is the ability to fine-tune modules without stopping production. Adjustments can be performed remotely via tablet or HMI while the line remains active.

Operators can:

This real-time control reduces downtime and improves overall equipment effectiveness (OEE), while lowering operator workload in demanding production environments.

Automatic Product Holder Monitoring
The FHF FlexControl integrates automatic detection of defective product holders. If a holder fails, the system stops it at a dedicated maintenance station.

This eliminates:

Operators can replace holders directly, maintaining line continuity and reducing intervention time. The automated detection system increases process reliability and reduces unplanned breakdowns.

Mobile HMI for Real-Time Process Control
Unlike fixed HMI stations, the tablet interface allows operators to stand directly in front of the module being adjusted. Parameters can be modified while simultaneously observing mechanical response.

This improves:

Continuous monitoring through either tablet or fixed HMI ensures faster diagnostics and more stable production performance.

Scalable Implementation and Operational Results
The installation of the FHF FlexControl was completed with technical support from JBT Marel engineers, enabling rapid transition from setup to full production.

Boscher Volailles reports:

A fifth FHF FlexControl line is planned to process an additional weight range, further expanding processing flexibility.

For poultry processors seeking to optimize front half deboning yield, reduce downtime and implement more precise, adaptable line control, the FHF FlexControl demonstrates measurable operational benefits in high-throughput environments.

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