FAQs
FAQ's
Process Overview
How does the Low Atmospheric Pressure Stunning (LAPS) system work?
LAPS humanely stuns birds by gradually reducing atmospheric pressure in a sealed chamber. As the air pressure drops, birds experience mild hypoxia (reduced oxygen), leading to loss of consciousness without the use of gas or electrical current. The decompression process takes 4-5 minutes, depending on bird size and welfare parameters.
Animal Welfare & Compliance
Is LAPS considered a humane method of stunning?
Yes—numerous welfare bodies, including the European Food Safety Authority (EFSA) and the Humane Slaughter Association (HSA), have reviewed LAPS and acknowledged its welfare benefits. Birds remain upright, unshackled, and unconsciousness occurs without exposure to aversive gas or painful electrical currents.
Are there visible signs of distress in birds during the LAPS process?
Validated studies (e.g. HSA Workshop Report) show minimal visible distress. Most birds sit or lie down quietly as pressure falls. Observed welfare indicators,such as wing flapping and vocalisation, are significantly lower than in gas or electrical stunning systems.
How is bird welfare monitored during LAPS operation?
LAPS chambers are fitted with continuous pressure sensors, timing controllers, and cycle data loggers. Each stunning cycle is recorded, ensuring decompression profiles are within welfare-approved limits. Many systems include welfare audit report functions that are exportable for compliance.
Is individual bird stunning monitored in LAPS?
Unlike shackling or electrical baths, LAPS stuns entire modules or drawers of birds simultaneously. Welfare control focuses on the decompression rate and chamber consistency rather than individual bird monitoring, reducing variability and risk.
How quickly do birds lose consciousness in LAPS?
Birds typically lose posture and consciousness between 60 and 120 seconds into the decompression phase. Time varies based on bird weight, age, and chamber profile settings.
Comparisons
How does LAPS compare to gas stunning?
LAPS offers a low-stress, gas-free alternative to traditional gas stunning systems. While gas stunning is effective, it involves exposure to gases that may require additional safety precautions and can introduce variability in the stunning process. In contrast, LAPS eliminates the need for gas exposure, providing a consistent and stress-free experience for the animals. It also reduces the risks associated with moving parts and handling live birds, prioritising staff and animal welfare.
How does LAPS compare to electrical stunning?
LAPS is a low-stress, gas-free alternative to electrical stunning. It eliminates the need for shackling live birds and reduces staff exposure to moving parts. Stunning is consistent and meets or exceeds welfare requirements across multiple assurance schemes.
How does the LAPS system compare to gas stunning in terms of cost and environmental impact?
Unlike gas stunning systems, LAPS does not rely on CO₂ or any other consumable gases. This eliminates ongoing costs for gas procurement, storage, and delivery infrastructure. More importantly, it removes a major source of greenhouse gas emissions from the stunning process—offering both immediate operational savings and long-term carbon footprint reduction. LAPS supports sustainability goals without compromising welfare or efficiency.
Meat Quality Implications
How does the stunning method affect meat quality?
Stress before and during stunning increases muscle glycogen depletion, affecting meat pH, colour, water retention, and tenderness. LAPS significantly reduces pre-stun stress by avoiding shackling and electrical shock, resulting in improved carcass quality.
Is there evidence that LAPS improves shelf life or reduces defects?
Yes —lower pre-slaughter stress leads to fewer defects like blood spots, bruising, and broken bones. Improved initial pH stability and lower stress hormones can extend shelf-life by up to 24 hours compared to electrical stunning systems.
Can LAPS reduce carcass damage rates?
By eliminating shackling and minimisinghandling, LAPS dramatically reduces wing damage, bruising, and broken bones. ProLoad-compatible systems further minimisedamage during module transfer.
Are there any differences in meat colour or texture with LAPS?
LAPS-treated birds typically show slightly paler meat due to reduced stress-induced muscle contraction. Texture is often more uniform, with a lower risk of pale, soft, exudative (PSE) meat resulting fromrapid pH decline.
Operational & Regulatory Questions
What happens if there is a power failure or system fault?
All systems include emergency protocols,such as backup air release valves, fail-safe modes, and manual override options. We also recommend UPS systems and generator backup for critical components. Safety and compliance don’t stop if the power does.
What is the capacity of the system in birds per hour?
System capacity depends on drawer configuration, LAPS chamber size, and line speed. We typically design for capacities ranging from 4,000 to 12,000 birds per hour. A capacity study is an integral part of our system planning, ensuring the solution meets your targets with room for future scaling.
How often does the system need servicing or maintenance?
Routine servicing is recommended every quarter, accompanied by daily operator checks. Our designs feature quick-access panels, lubrication-free components where possible, and fault diagnostics to reduce downtime. We also offer annual servicing plans for peace of mind.
Would you recommend purchasing spare parts fora system?
We recommend ordering an essential spare parts list when purchasing a LAPS system to ensure optimal performance and minimal downtime. This list includes smaller, standard parts needing replacement over time, such as seals, sensors, or other key components. Having these parts on hand means you can quickly address any maintenance needs without waiting for deliveries, helping to keep your system running smoothly and efficiently. We’ve designed LAPS with reliability in mind. Still, regular maintenance and timely replacement of parts are crucial to extending your system’s life and ensuring it meets welfare standards. Feel free to contact us for more information on the recommended spare parts for your LAPS system!
Is operator training required for these systems?
Yes, but it’s designed to be straightforward. We provide completeon-site training and documentation. Operators are trained on system start-up, cycle monitoring, drawer handling, and cleaning routines. In most cases, new users can be trained within one shift.
How do you manage cleaning and washdown in these systems?
All equipment is washdown-ready, with easy access to conveyors, drawer runners, and external LAPS components. We design for sloped drainage, remove unnecessary niches, and reduce cleaning time through modular access. This helps meet hygiene and biosecurity standards.
Is LAPS approved for use under the current EU and UK welfare regulations?
Yes —LAPS is approved by DEFRA in the UK and under EU Regulation 1099/2009 for poultry stunning, provided it adheres to welfare thresholds and validated decompression profiles.
Can a plant operating LAPS achieve Red Tractor, RSPCA Assured, or other welfare certifications?
Yes —provided the system operates within welfare scheme parameters. Some schemes may require specific decompression rates, recordkeeping, or welfare oversight during operation.
Are any special welfare measures required for LAPS operators?
Although the system is enclosed, reducing direct handling of live birds, operators must be trained in its use, understand animal welfare principles, and be aware of emergency procedures related to pressure control and equipment failure.
Does LAPS pose any sort of threat to operators?
Unlike gas stunning, LAPS poses no risk of asphyxiation to staff. However, operators must follow standard operating procedures (SOPs)for chamber access and pressure release. Noise levels are minimal compared to gas systems
What happens if the LAPS cycle is interrupted mid-stun?
The system is designed with automatic fail-safes to either complete the cycle safely or return the chamber to atmospheric pressure within a welfare-acceptable window. All systems should include backup power, manual overrides, and documented emergency procedures.
Scientific and Ethical Questions
Is there independent scientific research on LAPS?
Yes — to see a list of articles and research on LAPS, please see our resources page.
Are any species-specific welfare considerations necessary?
Yes —heavier birds or different poultry breeds may require adjusted decompression profiles. LAPS systems are designed with programmable settings to account for this.
Stunning Performance Monitoring
How is stunning effectiveness verified post-LAPS?
Post-cycle, a sample of birds is checked for consciousness using protocols such as the corneal reflex and posture loss. Audits confirm unconsciousness before slaughter. Data logs provide traceable assurance.
What data does the LAPS system record?
FAQ's
Pro-Load Live Bird Handling System- by Wrightfield
What is the Pro-Load Live Bird Handling System?
The Pro-Load is an advanced, fully automated live bird handling system developed for poultry processing plants. It efficiently unloads, processes, washes, and reloads transport modules carrying live birds. The system is designed to minimize manual handling, optimize throughput, improve biosecurity, and enhance animal welfare. Itis compatible with systems like LAPS (Low Atmospheric Pressure Stunning).
Where is the Pro-Load system typically used?
Pro-Load is used in poultry processing plants to manage the live bird intake process from farm transport modules to the processing line. It can be integrated with controlled atmosphere stunning systems, including LAPS, for humane, compliant, and efficient operation.
What module sizes does the Pro-Load system accommodate?
The system can handle transport modules in 3-, 4-, or 5-tier configurations, providing flexibility for various farm and plant setups.
What is the Pro-Load system made of?
- Transport Modules: Galvanised mild steel frames with plastic drawers in 3, 4, or 5 tiers.
- Module Circuit: Includes infeed conveyors, hydraulic scissor lifts, shuttles, module washers, and take-away conveyors.
- Drawer Circuit: This circuit features push-out towers, transfer conveyors, turn units, accumulation conveyors, hang-on stands, inverters, and drawer washers.
- Water Filtration System: A rotary screen with back-purge cleaning and an adjustable weir, ensuring adherence to hygiene standards.
- Control System: Touchscreen HMI, centralised control cabinets, variable speed drives, and real-time data monitoring.
Are there optional upgrades?
Yes, including:
- Module de-stack/re-stack systems
- Automatic drawer reloaders
- Drawer dip tanks
- High-capacity shuttles
- Custom water filtration upgrades
What are the Key Benefits of using a Pro-Load system
- Fully automated operation for improved efficiency and reduced manual handling.
- Enhanced biosecurity with integrated washing systems for modules and drawers.
- Heavy-duty, hygienic construction using stainless steel and galvanised mild steel.
- Flexible modular configurations to suit different processing plant capacities.
- Optional automatic upgrades for high-throughput operations.
- Data-driven operational control with touchscreen HMI and system networking
Can you expand on the main Technical Details
- Modules: Galvanised mild steel, approx. 650lbs each.
- Conveyors: Stainless steel frames with heavy-duty plastic modular chains.
- Hydraulic Scissor Lifts: Fast-action safety curtain and non-return valves.
- Washers: Stainless steel with quick-release jet banks and pneumatically controlled doors.
- Filtration: Rotary screen down to 1mm debris, adjustable and self-cleaning.
- Control: Centralised HMI with variable speed control, network-ready for data tracking.
Can the Pro-Load system be used with a LAPS (Low Atmospheric Pressure Stunning) system?
Yes —Pro-Load is fully compatible with LAPS systems, allowing for humane, stress-free stunning via gradual decompression before processing.
How does Pro-Load interface with a LAPS system?
It unloads transport modules and routes loaded drawers to a LAPS chamber. After stunning, the drawers continue through Pro-Load’s drawer and hang-on circuits for processing.
What equipment modifications are needed for LAPS integration?
- Custom transfer conveyors to and from the LAPS unit.
- Accumulation conveyors tailored to stunning cycle times.
- Integrated HMI control for process synchronisation and data management.
What are the benefits of Pro-Load with a LAPS system?
- Enhanced animal welfare and compliance.
- Seamless operational flow with reduced manual handling.
- Improved hygiene with automated washing.
- Integrated data monitoring for both systems.
Does Wrightfield provide integration support?
Yes —Wrightfield offers full layout design, interfacing solutions, and after-sales support for Pro-Load and LAPS installations.