Company Description

Feed Mill Poultry Houses for Parent Stock Hatchery Layer Maintenance System and Broiler Maintenance System (houses for rearing birds, houses for commercial birds) Egg Grading and Packing House Egg Processing Plant Slaughtery and Meat Processing Plant Storage Production Facilities

Hatching Eggs Production

Some of the most effective breeds (Lohmann layer breed and Ross broiler breed) are used at the poultry farm. Parent stock is delivered from Germany. The parent stock is kept in a separate site. Poultry houses have automatic feeding system, drinking system and ventilation system which ensure optimum temperature and humidity control; there is also a floor management system on slats and deep litter and automatic nests for hens. Hatching eggs are collected three times a day into specialized containers, disinfected and then sent to the hatchery.

	Bird maintenance system The total number of birds at the current moment is more than 2.6 million.   A lot of attention goes to the feed. Having the own feed mill makes it possible to prepare balanced feed with assured high quality. The feed mill produces 6 kinds of mixed feed for all ages of layer birds and broiler birds. Balanced feed with vitamins guarantees eggs with hard shells, increased contents of vitamins, bright yolks and excellent taste.
	The poultry houses are often renovated and the equipment for bird maintenance have been modified; this helped to double the bird number, cut transport, power and labour costs. At present the bird performance (efficiency, feed consumption, water consumption, and air exchange) can be controlled by computer.   Using the modern technology methods for bird maintenance allowed achieving the production of 602 million eggs per year.

 Egg Grading and Egg Packing

	All the activities connected with egg production are automated, so the first person to touch the egg is the buyer who opens the egg package at home.   Eggs are transported from poultry houses to the egg grading house with the air conditioned egg conveying system.   For the grading and packing of the eggs, modern egg-grading machines from МОBА (the capacity is 120 thousand eggs an hour) and DIAMOND (the capacity is 140 thousand eggs an hour) are installed. Recently an even more powerful MOBA egg-grading machine (for 180 thousand eggs an hour) has been installed.
	The egg-grading machine is controlled by a computer and the following operations can be carried out: egg washing separation of cracked eggs, with both visible and hidden cracks egg grading according to weight packing in different containers Use of automatic stacking systems help to decrease the percentage of cracked eggs.

Egg Processing

	Egg Processing is done at a newly built plant; it was built in 1999. In 2004 its capacity was increased with 70%. Modern equipment and flexible technology provide separated yolks and whites, dry egg products and liquid and frozen egg products.   The egg breaking line that is installed at Roskar is one of the biggest in Russia for the current moment; its capacity is about 80 thousand eggs an hour. The egg breaking line is fully automated and it’s possible to control all the steps of breaking process, the human factor and the possibility of finding foreign materials in egg products are minimized in order to obtain a high quality finished product. This technology is the most used egg processing method in Europe.
	ROSKAR Poultry Farm has its own laboratory equipped with modern laboratory equipment; it provides fast and effective analyses, so safety of finished products is guarantied   Thanks to world technology methods the processed products have an excellent taste, keep their energy value and all vitamins and nutrients contained in fresh egg. in fresh egg.   ROSKAR Poultry Farm is one of a few companies in Russia that produces liquid egg processed products in aseptic packages with long shelf life. It is also possible to adjust dry matter content according to the customer’s demand.
	It is possible to add different ingredients to egg products according the client’s demand. The technological possibilities of the poultry farm allow changing their parameters: solubility, emulsification power, whipping power, etc.   After having bought an egg-boiling machine (its nominal capacity is 14 thousand eggs an hour) a new product appeared in the range of egg products: boiled eggs in brine, packed in plastic buckets with 75 eggs or 150 eggs.   Recently a new omelet line has been started; it is fully automated and is used for the production of frozen, ready-to-eat omelets. There are no similar machines in Russia yet.

Meat Processing

	Besides egg products the poultry farm also produces high quality poultry meat and ready-to-cook products from broiler meat.   Dutch equipment is used for broilers maintenance, and it’s possible to adjust the required lighting, temperature, feeding and drinking. The parent stock of meat cross ROSS-308 is brought from Finland.   The slaughter of birds is done on the Dutch line of high capacity (6000 broilers or 4000 layers per hour). In 2008 it is planned to achieve a production 10 thousand tons of poultry meat.
	Different machines are used for meat processing to produce a wide range of products. In 2002 a new further processing line was installed to produce ready-to-cook and ready-to-eat products up to European standards.   Among the poultry meat products are cooled meat parts (chicken legs, chicken thighs, chicken breasts, chicken hams, and chicken fillets), different kinds of cooled and frozen poultry meat cutlets, poultry meat in marinade, brine poultry meat, ready-to-eat cutlets.

Product Quality Control

1. It’s necessary to analyze risks at all the steps of every technological process, in other words, it’s necessary to find out and list the risks that are likely to appear during the production process, it’s also necessary to work out the preventive steps to avoid the risk.
2. It’s necessary to reveal the Red Control Points (RCP) for every step of the technological process, to work out and do the appropriate steps for every dangerous item.
3. It’s necessary to determine the critical limits of the process. . It’s necessary to determine the control procedure for the RCP, in other words, it’s necessary to work out a system for regular RCP watching and measuring to be sure that RCP state is within the limits.
4. It’s necessary to work out the corrective actions in the case of deviation from the critical limits.
5. It’s necessary to work out and to practice effective registration methods, showing how the system is carried-out; to appoint the persons responsible for realization and for the documentation of technological operations and corrective measures.

Storage and transportation system

The company has all the necessary facilities for storage and punctual transportation of its products. There are cold stores with a capacity of 1000 ton and temperature controlled egg storage rooms. The transportation is done with special trucks.