High-quality cutting lines offer processors the solutions to deliver everything they need on time. The lines position the pieces automatically and produce high yields regardless of the set-up processors they use.
High-speed cutting lines provide poultry processors with the widest range of flexibility in direct relation to production capacity, said Garðabær, Iceland-based Marel, with offices in Lenexa, Kan. Production for quick service restaurant chains, retail and other food service customers may differ in how the bird is cut or the specific cuts required.
Poultry processors face many challenges in their industry today and have a variety of reasons to consider automation. A shrinking workforce and the need to feed a growing world population are just a few. Incorporating fully automated or semi-automated high-speed poultry cutting gives processors options to overcome operational bottlenecks, Marel added.
Quality cutting
“A complete cutting line contains hanging station, wing stretcher, wing segmentation, whole wing cuts, front half cut, (or breast processing machine) tail cutter, leg processing machine, drum cutter and thighs (or saddle divider in the case of a quarter leg),” said Oliver Hahn, CEO of Kansas City, Kansas-based Baader Poultry.
But the most important poultry cutting line attributes for processors to get the greatest return on investment (ROI) are “Reliability, Efficiency and Quality,” said a poultry processing technology expert from acquired Cantrell- Gainco, Gainesville, Ga. from Birmingham, Ohio-based Bettcher Industries in March 2019.
In addition to components and overall quality, die lines must meet the changing needs of the processor and the changing demands of the industry. Improved food safety and design and manufacturing to improve chain life and bird movement control during processing also play a major role in cutting line value.
“Automation, visual technology and weighing capabilities further contribute to higher quality and increased productivity,” Hahn said.
As poultry processors make decisions about the potential purchase of high-speed cutting lines, many factors, above and beyond ROI, must be considered.
In addition to reliability, efficiency and quality, “high-quality parts availability and service,” are the most important factors poultry companies should consider when purchasing a cutting line, poultry processing expert Cantrell said.
These qualities and attributes play a large role in today’s drive for automation. The effectiveness of automation depends on the longevity and ability of the company to take advantage of the automated processes. Without the quality and reliability and the means to keep the line running, automation does not serve its purpose.
“With the industry’s labor shortage challenges, automated or semi-automated systems have really given poultry processing facilities the ability to increase production and control many critical efficiencies in their production lines,” added Cantrell’s expert.
Hahn added that Baader is always working to improve and enhance the performance and reliability of existing technologies, as well as add functionality with new technologies.
“For high-speed cutting lines, we have incorporated built-in anatomical segmentation of the wings in the bypassable cutting line, resulting in significant labor savings and the elimination of additional transport steps,” he said. “This integration allows for seamless productivity and increased efficiency, especially when coupled with automatic deboning machines.”
User friendly
Cantrell’s expert said that adapting to the latest technology, such as automated deboning machines, entering the industry is the best way poultry processors can take advantage of the opportunities that producers are offering. Hahn said the latest high-speed cutting technologies include visual grading, built-in weighing and the ability to bypass individual birds in each unit.
“Using these technologies, processors can send the birds to the correct unit to achieve the best cutting performance and optimal yield,” he added.
Suppliers must train poultry processors and give operators as thorough an understanding of the equipment as possible to ensure that companies and their teams get every bit of efficiency, reliability, high yields and consistency available in a high-speed cutting line. At Cantrell-Gainco, an experienced sales staff begins this process at the beginning of the processor-supplier relationship.
“The second most important thing is having a reliable and skilled service team that has access to high quality parts,” added the Cantrell expert.
Collaboration between suppliers and processor customers to fully implement automated, high-tech cutting lines involves not only education, but also the basic, hands-on training that goes with it.
“Baader emphasizes the importance of a skilled service force that provides the necessary training, supported by in-depth manuals, troubleshooting materials, support training videos and manuals,” Hahn said. “Establishing close relationships with customers provides valuable input for future developments. In addition, Baader offers preventive maintenance contracts with all of our cutting units to ensure optimal functionality and cutting performance.”
Manufacturers are constantly working through research and development to create new cutting technologies, as well as introducing new ideas to apply to existing technologies in an effort to offer processors the best possible high-speed cutting solutions, especially when it comes to higher yields with less labor.
In-process data capture has become the norm for all businesses, and food processing equipment manufacturing is no different.
“The integration of intelligent automation captures data on each bird, determining the best route within the cutting line to maximize production efficiency,” Hahn said. “Baader also emphasizes customer training and support for successful automation implementations.”
Top row
Baader offers its ProFlex Cut-Up System as a customized solution serving the diverse needs of every poultry processor. The system includes on-board weighing, on-board visualization system, front half knife, anatomical wing segmentation, saddle separator, leg processor, hip and thigh knife and unloading device.
“Customers benefit from Baader’s solutions through high yield with low labor and quality reduction without compromising product quality,” Hahn said. “Efficient automation, flexibility in creating different wing products and reduced trimming labor ultimately results in increased yield.”
Cantrell-Gainco offers poultry cutting solutions that include portioning and segmentation systems that are flexible enough to meet the requirements of any processor. Its high-performance systems ensure optimal yields and finished cuts while minimizing labor and material handling costs. The company’s equipment also has the ability to meet the specifications set by food service, institutional and other customers.
Marel provides poultry processors with many options for poultry cutting lines. Marel offers complete, semi-automated and entry-level automated cutting for processors looking to enter or add next-level cutting lines to their operations.
For poultry companies seeing steady growth in cutting volume, or those looking to move from whole birds to parts, Marel’s ACM-NT Compact system gives poultry processors easy access to automated cutting and is for facilities with limited space. The system is modular with the flexibility to create any chicken part(s) and can be custom designed or upgraded.
Marel semi-automated cutting combines automated and manual processes in a taper line. Also upgradeable, manual operations can be replaced with automated modules to service processors as needed. For all of its cutting lines, Marel offers remote technical assistance and on-site technical assistance to address problems and prevent downtime while increasing productivity and efficiency.
