Raw materials received by the feed factory under contracted business relations are tested in chemical and microbiological laboratories in accordance with the terms of the contract. Only the raw materials which comply with the standards are accepted, and out of standard materials are rejected. The raw materials which are accepted are piled up in predetermined storages. If stocking process is expected to a take long time, protective measures are taken against mold formation and toxins.

Production

Initially, raw materials needed for production are taken into dosage silos. Ratio of the feed to be produced is prepared based on the type of animal and the level of productivity. Production is performed with a fully automated computerized system. Each stage of production is continuously controlled by taking samples at each stage of processing and analyzing the feed in NIR device within 2 minutes.

All feeds transported to hatcheries are quickly analyzed in NIR devices just as during the production process and are sent to the field upon receipt of conformity report issued by the laboratory.

Production process continues, after the carcass chopping process, as a part of the products are sent to the further processing and delicatessen units. In the further processing pre-preparation department, raw materials are transformed into mixtures in accordance with the product formulations. This mixture is shaped in automatic machines using the moulds designed for that particular product, and then conveyed to cooking department following liquid and dry coating.

Cooking stage is a computer controlled process consisting of fry cooking and steam cooking. Fully cooked products are taken into multi-storey freezer with -40°C ambient temperature, and internal temperature of the product is brought to -18°C. The product is then packaged and stored in deep-freezes until shipment.

Delicatessen production consists of pre-preparation, cooking and packaging phases. Mixture prepared in the pre-preparation department in accordance with the product formulation are automatically filled by filling machines, taken to cooking carts and cooked in ovens under computerized control system.

The products are first taken into resting units and then packaged and stored in cool storages until shipment. The storage area consists of fresh and frozen sections. The products are monitored under computerized environment based on first-in-first-out principle. The products in the storages are shipped to dealers in pre-washed and disinfected freezer trucks.

Each health control stage of incubation eggs produced under BIO safety measures and hygienic conditions is regularly performed by veterinarians in charge.

Development and health condition of the chicks during rearing, are periodically controlled by veterinarians and agricultural engineers in compliance with the EU standards in hatcheries, where they stay for 45 days.

Both raw materials and feeds are subjected to microbiological and chemical (nutritional) tests in the laboratories. Presence of toxin, mold, salmonella, E.coli, total coliform, enterobacteria in the raw materials and feeds are controlled in microbiological tests.

In chemical tests, moisture, raw protein, raw fat, raw cellulose, raw ash, starch sugar, metabolic energy, acidity, peroxide value and solutions in the raw materials and feeds are checked through infrared systems.

In mechanical tests, pellet durability index (PDI) of the feed, crumble particle size and mixer sieve particle size of powder feed are checked. Foreign material and broken grain percentages in the raw materials are tested.

Mineral substance analysis in feeds, raw materials and feed additives are performed using Spectrometer and Titration devices.

Following all of the abovementioned steps, initially slaughtering is done according to Islamic rules in the slaughterhouse. Slaughtered chicken is automatically processed in high technology machines.

Hens are transformed into carcass meat, cut in portions, packaged, labeled and taken into cold storage for aging purposes in the facility, which is inspected by in-house food engineers and veterinarians at every stage of the production process.

Göynük Slaughterhouse
Capacity of the Göynük Slaughterhouse is 10,000 chicken per hour and 150,000 chickens per day.
Our slaughterhouse operates on shift system. Slaughtering is performed in 2 shifts; whereas 1 shift is allocated for cleaning and disinfection activities. The most important and indispensable activities in the slaughterhouse are cleaning and hygiene.
Our slaughterhouse has been given the HACCP, TSE and ISO certificates, and has also received the European Union Advance-Fixing Certificate. Production phases are controlled by in-house engineers and veterinarians.
Our slaughterhouse consists of slaughtering, cutting, delicatessen, and further-processing product departments, where there is always a product for every unique taste.
Our slaughterhouse is a fully environmentally conscious facility where post-treatment water is used for agricultural and cleaning purposes.

Bolu Slaughterhouse
Capacity of the Bolu Slaughterhouse is 10,000 chicken per hour and 150,000 chickens per day.
Our slaughterhouse operates on shift system. Slaughtering is performed in 2 shifts, whereas 1 shift is allocated for cleaning and disinfection activities.
The most important and indispensable activities in the slaughterhouse are cleaning and hygiene.
Our slaughterhouse has been given the HACCP, TSE and ISO certificates, and has also received the European Union Advance-Fixing Certificate. Production phases are constantly controlled by in-house food engineers and veterinarians.
Our slaughterhouse consists of slaughtering and cutting departments.
Our slaughterhouse is a fully environmentally conscious facility where post-treatment water is used for agricultural and cleaning purposes.

Our breeding facilities are located in Bolu and Göynük. The breeding facilities consist of two sections called raising and egging.

Every stage of the production process is regularly inspected by our agricultural engineers and veterinarians at our breeding facilities

State-of-the-art technology is employed in the breeding facilities. Our company's principle is to place human health on the top of our agenda in all production processes.

Incubation eggs are transported to incubation house facilities in Bolu and Göynük with special egg carrying vehicles under hygienic conditions and biological production process begins. After selection process and disinfectation process of incubating eggs coming from breeding units, they are placed into incubation machines. All phases are adjusted and monitored electronically in computer controlled machines in Turkey's most modern plant.

Erpiliç has capacity of 80 million incubation eggs per year. 70 million of broiler chicks are produced in incubation units per year. After 21 days incubation phase, the chicks hatched from eggs are transferred to temporary growth coops after health controls performed by vets.

There are three pieces of incubation facilities in our company. These facilities are fully equipped with modern machinery.

Incubation facilities use cutting edge technology.

All stages of production are controlled by agricultural engineers and the veterinarians.

Each phase of hatchery production is done according to hygienic rules.

All productions are primarily in the forefront of people's health.

Quality raw materials are treated in special processes and sanitized. The raw materials are passed through airborne bacteria capturing filters and then feed is produced. Annual production capacity is 330 thousand tons.

Broiler chickens at desired live weights are inspected by Erpiliç veterinarians before and during slaughtering process. Slaughtering process is conducted in accordance with Islam rules. Chickens are automatically processed in high technology machines and then taken into chilled storages.

Salami, sausage, soudjouk, patty, burger and folded chicken products are produced using special seasonings and additives procured from leading companies worldwide, and offered to consumers with the touch of Erpiliç flavor.

Göynük Feed Factory: Our feed factory, consisting of 35,000 m² outdoor and 5,500 m² indoor areas, has 330,000 tons of mixed feed production capacity on annual basis. Göynük Feed Factory is made up of two units called breeding feed production unit and broiler feed production unit.

Bolu Feed Factory: Our feed factory, consisting of 60,000 m² outdoor and 4,500 m² indoor areas, has 220,000 tons of mixed feed production capacity on annual basis.

MAIN STAGES OF THE SLAUGHTERING PROCESS:

LIVE CHICKEN RECEPTION, SLAUGHTERING AND DEFEATHERING
EVISCERATION
AIR CHILLING
WEIGHING, QUALITY DETERMINATION AND CUTTING
PACKAGING, STORING AND SHIPMENT
FURTHER PROCESSING DEPARTMENT

1. LIVE CHICKEN RECEPTION, SLAUGHTERING AND DEFEATHERING
Chickens are checked prior to slaughtering in compliance with the legislation in force and the norms of the European Union. When the chickens are brought to the slaughterhouse, their final check is performed by public veterinarians and in-house veterinarians. Upon approval of the veterinarians, the chickens are conveyed to the slaughtering section and the slaughtering process begins. The first phase is the live chicken reception unit. Vehicle carrying the chicken to be slaughtered approach the live chicken reception platform by receiving required information. Plastic crates full of chicken are automatically unloaded from the vehicle and placed on the operating band conveyor. Workers take the chickens from the crates and hang on the carousel. Empty plastic crates and the vehicle are washed and disinfected. The crates are loaded on the vehicles, which leave the slaughterhouse in order to be prepared for the same process in the following slaughtering day.In the meantime, the chickens hanged in shackles are hand-cut by the experienced and trained butchers according to Islamic rites. After that, blood is drained out of the carcass and then scalding process takes place in feather softening tank where chickens are prepared for defeathering. Subsequently, head is removed from the body and the headless carcass transferred to the evisceration line. During transfer process, feet of the chicken are cut using feet cutting machine.


2. EVISCERATION
Chickens are conveyed into the evisceration machine, and stomach area of the chicken is perforated. Evisceration machine completely removes internal organs of the chicken which come to the machine. The internal organs continue on the line towards the giblet separation machine, in which intestines and gall bladder are separated. Automation process continues in the subsequent stages. Chickens without internal organs are entered into the throat control machine where maws are removed and the chickens are passed to neck breaking machine. Chickens' necks are removed by the machine. Following removal of the necks, neck skins on the chickens are cut by a machine; and then the chickens are taken into the machine for complete washing including inside and out side. The machine washes inside and outside of the chickens using pressurized spray water. The chickens which are washed are sent to air chilling unit for chilling purposes.


3. AIR CHILLING
Since air chilling process is employed in our plant, microbiological criteria are fully satisfied and the best flavor is achieved. Air cooling units consist of 5 sections containing 3,500 meter long three storey conveyor lines. The chickens enter the air cooling units at 36 degrees temperature and are cooled down to maximum four degrees in the center as they leave the units. The chicken stay in the air chilling units for about 2.5 hours.


4. WEIGHING, QUALITY DETERMINATION AND CUTTING
The chickens which come out of the air chilling unit are passed to an automatic transfer machine equipped with a scale, where they are both weighed and transferred to the determination unit. The chickens which are weighed pass through the quality classification station and then fall into grammaging sections in accordance with the weight ranges and the qualities determined in the computer. The chickens which fall into the pans are first bagged and then packaged as whole carcass and sent to the stockroom. The chickens to be chopped do not fall into the pans and continue their way hanging on the conveyor. Then they are transferred to the cutting line via automatic transfer machine, and are delivered to the cutting modules based on the products to be produced. Pieces of the chopped chickens are separated into their respective sections, controlled for one last time, packaged and quickly taken to cold storage rooms.


5. FURTHER PROCESSING
Certain portion of the products produced at the cutting department is send to delicatessen units for further processing. In the further processing pre-preparation department, raw materials are transformed into mixtures in accordance with the product formulations. This mixture is shaped in automatic machines using the moulds designed for that particular product, and then conveyed to cooking department following liquid and dry coating. Cooking stage is a computer controlled process divided into two phases: fry cooking and steam cooking. Fully cooked products are taken into multi-storey freezer with -40°C ambient temperature, and internal temperature of the product is brought to -18°C. The product is then packaged and stored in deep-freezes until shipment. Delicatessen production consists of pre-preparation, cooking and packaging phases. Mixture prepared in the pre-preparation department in accordance with the product formulation are automatically filled by filling machines, taken to cooking carts and cooked in ovens under computerized control system. The products are first taken into resting units and then packaged and stored in cool storages until shipment. The storage consists of two sections called fresh and frozen. The products are monitored under computerized environment based on first-in-first-out principle. The products in the storages are shipped to the dealers by freezer trucks, which are washed and disinfected.