Professional Documents
Culture Documents
INSIDE TRACK
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Global
Market trends
Master project
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Welcome to Atlanta
We are excited to welcome you to the 2013 International Production and Processing Expo in Atlanta. This years trade show is integrated with IPE, IFE and AMI bringing together over 1000 exhibitors and an anticipated 25.000 attendees from and different industries around the world. Exhibiting at this show is a great way for Foodmate to meet with existing and new customers and friends but also to demonstrate our latest innovations and technology. This show marks a special edition because it is celebrating 65 years of continual
special edition because during this show we introduce and unveil our highly anticipated OPTI -LTD Total Dark Meat Deboning System. The OPTI - LTD Dark Meat Deboning System is the rst machine on the market capable of deboning anatomical whole legs, thighs and drumsticks on the same machine. It is our latest development to help our customers nd ways to efciently debone dark meat. And it provides a solution that allows our customers to invest in exible automation so that they can quickly respond to the market. In addition to the OPTI LTD Dark Meat Deboner, we are also introducing the new series of OPTI Dark Meat Processing Solutions. This is a series of machines
that is specically designed to help our customers optimize dark meat yields and reduce labor. As a young company, we are proud of the depth of resources we have invested in innovation to bring new solutions to the poultry industry, helping customers nd ways to solve daily challenges, maximize yields and reduce labor. We hope you enjoy your time in Atlanta and look forward to seeing you.
exhibition services to the poultry industry! But for Foodmate this show also marks a
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Global
Market trends
Master project
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New Equipment
Eviscerating system
Equipment
Column
Larger birds
Another growing trend around the world is processing larger birds. We see in some markets bird sizes that go up to +/- 4 to 5 Kg or 8 to 9 lbs. This is of course an interesting development for many companies as it allows them to produce more Kgs or Lbs. with the same amount of labour, storage and overhead cost. But the ip side to this trend is the challenges it imposes on the processing equipment since most equipment is not suited to handle the increase in bird size. Foodmate studied the effects
that big bird processing has on equipment and we have been able to make positive improvements to optimize yield, uptime and cost of ownership.
The Foodmate OPTI thigh deboner can be modied to automatically produce Pirzola .
installed several cut-up lines around the world for various fast food purposes.
4 piece breast
Pirzola
Complete new high speed distribution and cut-up project in the heart of The Netherlands
About Van den Bor
Van den Bor is a well-known Dutch poultry processing company located in the heart of the Netherlands. The company is family owned and currently managed by the 3rd generation. Van den Bor is a traditional Dutch company that has grown steadily throughout the years which has allowed them to become a stable and efcient company that processes 125.000 birds per day. Hard work, great attention to detail and quality combined with excellent service has allowed Van den Bor to become the successful company it is today. Currently Van den Bor is in the process of increasing its slaughter capacity from 9.000 birds per hour to 12.000 birds per hour. The slaughter plant in Nijkerkerveen provides both sized whole bird or cut up parts to either their own debone plant in Meppel or to 3rd party debone companies in both The Netherlands and elsewhere.
Foodmate project
After an intense conceptual and pre-design period, Foodmate was awarded the order to carry out the entire project to completely restructure the distribution, cut up and packaging area. This involved: - A weighing transfer machine from the air chill line to a whole bird distribution line - Bird sizing, calibration and batching system - Delivery of 3 OPTI Flex Cut Up Systems
- All product distribution conveyors - Breast cap weighing, batching and packing system - Box and crate conveyor system All this had to be done under the following conditions: - Very accurate high speed sizing and grading - High reliability and up-time - Keep it simple and user friendly - Increase pounds per man hour - Increase capacity by 33% in the same space
- Mid wing cutter - Wing cutter Supercut - Breast cap cutter - Back cutter/front halve cutter - Saddle cutter - Leg processor S2 - Thigh & drumstick separator - Leg unloading station 4. Product distribution system - Wired belt conveyors with product tracks - Product chutes - Product box/crate weighing system - Product WPG system
5. Breast cap weighing system - 3 tiers belt weigher - Sizing system - Batching system 6. Box and crate transport system - Infeed and outfeed area for inline crate washing - Crate drip area - Several crates take-off stations In total this project can be seen as a complete and continuous ow process. All end products are coming together at a central point with easy access to the end product storage area.
1. Weighing transfer machine - Automatic transfer system up to 18.000 bph - Very accurate sizing (weighing) batching system for whole birds - Max + 10 grams/Min 10 grams weight difference - Easy and multifunctional Windows operated computer system
2. Distribution line - Drop off stations for whole birds - Bird collecting stations - Drop off station to the 3 cut-up systems - Based on a 8centre line 3. Flex cut-up systems - Wing stretcher - Wing tipper OPTI cut
The Netherlands
Project installation
The available time for installation for this project was very short. The customer had to run production until the very last minute. And due to the very tight workspace it was not possible to do any kind of pre-installation work onsite. This only left 72 hours to dismantle the existing equipment and construct, install and test the new system. With a well planned time schedule and a very experienced team of dedicated technicians, Foodmate completed the project within the available time, working 24 hours per day. The start up went very well and all of the 115.000 birds scheduled for that day were able too be processed and shipped to customers!
3D view
2D view
System high-lights
For this project Foodmate incorporated its latest developments and line of equipment. All of Foodmates latest developments are designed to meet the high-speed requirements of the customer, meet the latest hygiene standards and assure the best possible cutting, sizing and grading results. Some of the key components for high speed processing are: - All new weighing/transfer system The all new Foodmate WTS is designed to efciently transfer birds between the air chill and distribution lines and to accurately weigh and grade the birds at the same time. The machine has a simple but smart design and is Cut-up section very easy to operate and maintain. - New cut-up frames Foodmate saw this project as the perfect opportunity to also incorporate our newly designed cut up frames. The new frames are designed to meet the latest hygiene requirements by having an open design so that no dirt can drop onto the support frames underneath. Furthermore the cut up frames are electrically controlled making them easy to adjust and bypass. - Product and waste handling system All portioned products are Wing products and thighs: these product are handled via our innovative WPG system. Please read the article on page 15. Leg quarters: from all 3 lines the legs are presented to the packers inline. Either box or crate packing is possible on the same line and once packed all boxes and crates are weighed and labelled and are transported towards a central storage area by the same conveyor. Breast caps: are conveyed inline directly to the belt grading and batching systems. All breast caps from the 3 lines are following the same route on multi tier conveying belts towards the multi tier grader/batcher. Breast cap conveying transported to 3 different nal packing stations.
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Drum Bone Unloader
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Thigh Hanging Station
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Drum Meat Scraping Station
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Tendon Cutting Station
cost-effectively. Capable of deboning 100 skinless or skin-on anatomical whole legs, thighs and drumsticks per minute, this system is so exible that no additional parts or changes are required when switching between the various dark meat deboned products. The OPTI-LTD can process left and right legs at the same time, with no need to separate the legs. The machines exclusive concept and design produces high quality deboned dark meat with only a few trimmers and inspectors required. It removes the meat with low bone content left in the meat and leaves the pin bone on the drumstick. The innovative scraper design gives the meat a hand-cut appearance and produces extremely high yields. OPTI-LTDs all-mechanical design helps keep cost of ownership low. The system is very user-friendly, which helps continuous peak performance while keeping downtime to a minimum.
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Whole Leg Loading Station
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Meat Discharge Station
Key Benets:
- Debones 100 whole legs, thighs or drumsticks per minute - Designed to debone any size bird - Minimal bone content - less trimming required - Capable of meeting all boneless leg meat specications - Excellent yields - Can process both left and right legs at the same time - High output per operator - Simple all-mechanical design - user-friendly and easy to maintain - Low cost of ownership
Finished Product
Anatomic thigh
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complaint from machine operators and maintenance adjust height or width we always have to do a lot of work and this is very time consuming. To have an answer to this problem we can now offer standard manual height adjustment or electrical regulated adjustments. - Cutting: on several cut-up machines modications took place in order to give better yields, handle more weight ranges and handle higher speeds.
France
Laguillaumie France: dynamic airchill system and automatic line transfer
they process about 5000 birds per hour.
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Laguillaumie is a very well recognized Halal plant just 150 km South of the French capital Paris. This company processes according the highest Halal standard and is approved by the AVS certication authority. At Laguillaumie
In order to bring more efciency into the process the company decided to add a new building for installation of an automatic dynamic airchill system. Before Foodmate was involved, they used so called trolley carts and drove them into the cold storage to cool their birds. This process involved a lot of manual work and didnt improve the quality of the birds says Mr. Moussa (owner and president of Laguillaumie). With the new Foodmate airchill system and automatic transfer from airchill to our cut-up system the bird quality improved and we are making signicant labour savings.
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Vent cutter
Cropping machine
Opening machine
Neck breaker
Eviscerator
Final control
Perfect end product and low maintenance marks the Foodmate evisceration line
Inside/outside washer
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Turkey
Erpilic Turkey: OPTI Thighdeboner and Pirzola processing
meat is partially stripped down the bone leaving the bone still attached to the
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meat. This product is the perfect BBQ product as the bone and the skin give a wonderful taste and the meat stays tender.
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We are more than satised with the Foodmate OPTI Thigh deboner. The thigh deboning results are perfect and are even better in terms of yield and presentation then manual deboning. But for us in particular having the Pirzola functionality is very helpful, says Mr. Mete (General production manager at Er Pilic). The Pirzola product is really a big product in Turkey and before we only could do it manually which was very labour intensive. This machine signicantly reduced our labour cost and for us it is one of the best investments we have made in years.
Er Pilic in Turkey is one of the main poultry processing companies in Turkey and they have several processing plants around Turkey. The company works according the highest possible standards and is well recognized in Turkey and in the countries they export to. For the Bolu location Foodmate delivered a modied OPTI Thigh to make Pirzola. The Pirzola product is very popular in Turkey, specially during the summer season. Pirzola is basically a skin-on thigh from which the
Turkey
CP Turkey: Automatic breast cap deboning
For one of the Turkish main plants CP invested in a Foodmate automatic breast cap deboning system FM 7.50. This machine is capable of deboning breast cap at high capacities. The key benets of the FM 7.50 are: compact design, minimum amount of operators required, low maintenance cost, high yield and a perfect ready to pack end product. The machine
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The CP group is one of the largest poultry processing groups Worldwide. With processing plants all over Asia and in Turkey the CP group became a major player over the last decades. In Turkey CP also have several plants.
can debone buttery llets as well as single llets. At CP we looked at several solutions to debone our breast caps efcient in all possible ways. The Foodmate solution was by far the best option: good yields, low maintenance cost and a very compact footprint required, says Mr. Mustafa of CP Turkey. FM 7.50 breast cap deboner
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Hauwlerwijk location and in the middle of 2012 Heijs decided to purchase a second machine for their Leek location.
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It took a long time to become a preferred and respected KFC supplier. For a long time we doubted if using automation to cut according to KFC specications would not affect our reputation. But since we decided to install a 9 piece cut up system from Foodmate our KFC business has only grown. One of the main contributing parts to our success with KFC is the Foodmate 9 piece cut up system, says Mr. Jan Jaap Hamming of the Heijs company. We never expected the KFC market to grow this fast and
that we would need a second 9 piece cut up system within two years. The new cut up system at Heijs in Leek is a so called Combi Line, which means that in addition to producing KFC 9 piece, the line can also cut anatomical whole legs. This allows Heijs to produce more products in the same space at minimal additional investment.
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WPG system
WPG system
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The new digital manual gives all information needed and helps you to keep your machines running optimal. Worldwide
Foodmate B.V. Rntgenstraat 18, Oud-Beijerland P.O. Box 1405, 3260 AK Oud-Beijerland The Netherlands Phone: +31 (0)186 630 240 www.foodmate.nl
North America
Foodmate US Inc. 300 Wilbank Drive Ball Ground, GA 30107 United States of America Phone: +1 678 819 5270 www.foodmateusa.com
Upcoming events
2013 12-14 March CFIA Rennes, France 2013 13-15 March VIV Asia Bangkok, Thailand 2013 04-09 May IFFA Frankfurt, Germany 2013 22-24 May VIV Russia Moscow, Russia 2013 07-11 October Agroprodmash Moscow, Russia 2014 20-22 May VIV Europe Utrecht, The Netherlands