Technology
Poultry reproduction
The poultry reproduction unit of 2nd level is situated in branch Staroe Selo at Rogochev area. The technology of poultry raising has 2 periods:
1) raising of rearing birds up to 140 days with separate keeping of cocks and hens; 2) raising and keeping of parent flock from 140 till 440 days.
There are used broiler parental crosses of high reproductive performance ROSS-308 Habbard Flex. There are 6 poultry-houses to raise the rearing birds and 16 to keep the parent flock. At the branch there is egg warehouse with automatic conditions of initial disinfection and egg storage.
All poultry-keeping areas have automatic systems of feeding and watering of birds and automatic adjustment of ventilation and microclimate by leading European manufacturers.
Incubator
The factory has its incubator. In 2007-2008 there were changed all cabinet incubators and installed facilities by leading world manufacturers.
There are 6 incubator units with laying capacity of 76 800 eggs and 3 incubator units with laying capacity of 38 400 eggs.
The process of incubation is controlled by computer with automatic monitoring of: embryo temperature, automatic turn of trays, humidity in cabinets, level of ÑÎ2, cooling, ventilation and microclimate. Capacity of the incubator is 8 500 000 eggs per year.
  
Raising shop
The raising shop consists of 19 production areas. It has 475 000 bird spaces. All production areas have automated processes (watering, feeding, humidifying, ventilation, microclimate) by leading European manufacturers.
Combined feed production
At the territory of the factory there is combined feed shop with production capacity of 48 tons per day. The shop is equipped with the line of liquid components input that helps to optimize the fodder recipes. In 2006 in the context of energy saving program the cauldron using solid fuel was installed to warm the fat. The calculations to optimize the fodder recipes are made at software by Voronezh scientific research institute. There are 2 drying complexes for raw grain: universal round-robin dryer-10 (SKU-10), grain-drying complex SV-30G (KZSV-30G). 2 silos with automatic storage of grain and capacity 2 000 tons each were put into operation.
Slaughter and fowl processing shop
At the factory there is a slaughter and fowl processing shop with capacity about 10 000 heads per year. The shop was completely reequipped in 2006 and up-to-date systems by leading European manufacturers were installed.
The slaughter process has the following stages:
1. At first a bird is delivered to hang sector at start of production line, it is taken off the coop and fasten with the feet to the load carrier. The production line carries bird to the electric slaughter device. The bird is slaughtered with electricity automatically during 20 seconds. The metal cases with current are used as electrodes.
2. Draining of blood is made with a special channel during 90-120 seconds. Full draining of blood provides a good marketable appearance of poultry carcasses and increases the term of their storage.
3. Thermal processing of killed bird is made by hot water in special units. After being plumed the poultry carcasses on the production line get to afterplume sector. It is made manually and very carefully not to damage the skin. Feet are separated manually with knife. Emboweling of carcasses starts with the longitudinal section of abdominal cavity. Then bowels are taken out, livers and stomachs are separated.
4. After being weighed the production is packed and marked. Broilers are packed into plastic sachets and half-finished products are packed into polymeric trays and wrapped with tightening polyvinylchloride (PVC) film. The production is marked automatically at the labeller.
5. The production is cooled in water at temperature +4°C during 25 minutes. Then the poultry carcasses and half-finished products are sorted and frozen at temperature -12°C.
  
Sausage shop
At the factory there is a sausage shop with productive capacity about 480 tons per year. The sausage shop produces:
- Cooked sausage products;
- Fowl products;
- Chopped half-finished products (cutlets, forcemeats);
- Frozen half-finished products (pelmeni, chebureki);
- Mechanically deboned fowl;
- Half-finished products for animals feeding.
To improve the quality of the products there were installed: the press for mechanical afterdeboning of fowl, a vacuum packing machine (to prolong the fowl shelf-life), heat chambers with automatic control of parameters (for thermal processing of production).
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