IPPE Edition Volume 1 | 2013

INSIDE TRACK

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Global

Market trends
Master project

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Van den Bor The Netherlands

Market introduction

OPTI-LTD Dark meat deboner

New equipment

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Weighing/transfer system WTS

Welcome to Atlanta

Welcome to Atlanta Welcome to Foodmate

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.

David Hazenbroek President Foodmate BV

Scott Hazenbroek President Foodmate US, Inc.

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

New cut-up modules

Equipment

Van den Bor The Netherlands

Equipment

Eviscerating system
Equipment

Dark meat processing

Market introduction

Combi retail/KFC cut-up system

New

OPTI-LTD Dark meat deboner

Digital machine manuals

Column

Market trends from around the World

Worldwide, the poultry meat industry is constantly on the move. For us as a supplier to this dynamic industry it is very important to monitor these trends carefully. We would like to share with you our observations from around the world and maybe it will even give you some new ideas!

Boneless dark meat (worldwide)

In several parts of the world we see that the demand for deboned dark meat is becoming increasingly popular. In the past it was mainly Japan that used boneless dark meat but we now see that worldwide boneless dark meat is in greater demand. More often do we see that boneless leg meat is being sold as whole muscle meat in retail stores but it can also be found in both restaurants and fast-food outlets. People are starting to realize that dark meat is tastier and more tender then boneless breast meat. Another application we see for boneless dark meat is the so called Kebab and Gyros production. Kebab and Gyros is growing rapidly all over Europe and Russia.

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

Pirzola (mainly Turkey)

A very interesting product in our opinion is called Pirzola. Chicken Pirzola is very popular in Turkey. Pirzola is basically a skin-on thigh from which the meat is partially stripped down the bone leaving the bone still attached. This product is perfect on the barbeque or grill. The bone and the skin give a superior avour to the product and the meat stays juicy. The bone can be used as a handle to make eating easier and it keeps your hands clean. In Turkey this is sold as a premium product and is by comparison the most expensive poultry part. Specially when you take into consideration that the skin and bone are still attached.

Fast food poultry parts

Around the world and in particular in Asia and Russia we see that chicken fast food is getting bigger and bigger. When thinking about fast food we dont just mean processed poultry meats like chicken nuggets or burgers, but real bone in chicken parts like wings, thighs, breast pieces etc. We see a signicant growth around the world in chains like KFC. But also in the number of local brands that are serving fried or grilled poultry parts according to the local taste. These parts can vary from standard 8/9 piece cuts as well as up to 25 pieces (South Korea) or for example 6 piece breast pieces (USA). Foodmate is specialized in special cut-up and already successfully

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

3 piece leg quarter

Pirzola

Master project Van den Bor

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.

Project Scope Increase capacity from 9.000/bph to 12.000/bph

At the moment Van den Bor is increasing its capacity in phases from 9.000/bph to 12.000/bph. The increase in capacity has impact on all processes in the plant, but in particular it has a major impact on the distribution, cut up and packaging area. The end goal was to increase the overall capacity by 33% in the same limited space with the same amount of people!

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

The Foodmate approach

Foodmate approached this request as a great challenge and worked very closely with the customer during the entire project. By using the latest 3D engineering technology found a solution to put the pieces together. The total scope of equipment involved the following:

- 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.

Central packing section

Introduction to Dark Meat Processing

Worldwide there is an increasing trend and need for deboned chicken dark meat. This meat is often used as a whole muscle product or as a raw material for convenience foods. Each part of the world has its own unique application but in the end it is all about how to maximize yields with the least amount of skilled labor. Foodmate recognized the growing market trend for deboned dark meat more then 2 years ago and started developing various dark meat deboning solution. As a result, Foodmate also quickly realized that in order to get the maximum deboned dark meat yields that other parts of the process also had to improve. So rather then only focusing on a particular part of the process such as thigh deboning Foodmate decided to focus on the entire process, which we now call Total Dark Meat Processing Solutions. The result is the development of a series of new dark meat processing machines that all contribute to the highest possible dark meat yields. Foodmate line of OPTI Dark Meat Processing Solutions.

Front half cutting

To create a thigh with a nice full oyster it is important to start with a good front half cut so that the oyster stays on the saddle rather then the front half. This will help the leg processor to achieve maximum oyster retention and quality. Further more it is important to make sure the back is long enough so that the leg processor does not break the back during processing.

Foodmate OPTI FH Dual blade Front Half Cutting Machine

The new Foodmate OPTI - FH front half cutting machine uses two blades instead of one large blade, gives a straight cut across the hips and gives more control over the number of ribs that stay on the front half and the length of the back on the saddle. OPTI FH

Anatomical back removal

Removing the back from the saddle is one of the most challenging parts of the process. At the same time it is the most important part of the process to help maximize dark meat yields and to provide an A grade thighs for tray pack operations. Some of the most common problems found with automated leg processing include; high bone content, low oyster retention, dangling oysters, low yield and damaged knuckles.

OPTI PLUS and OPTI PLUS XL Leg Processors

The new Foodmate OPTI PLUS Leg Processor is specically designed to help maximize either bone in or boneless dark meat yields. To help ensure maximum oyster retention and to prevent oysters from falling of during thigh deboning, the machine leaves the membrane around the oyster. In addition the machine is designed to provide a high percentage of white knuckles with very low bone content. The OPTI PLUS XL Leg Processor is specically designed to handle so called big birds or large chickens. OPTI PLUS XL

Separating the thigh and the drumstick

Separating the thigh and the drumstick is a very important part of achieving maximum bone-in and boneless thigh meat yields. Often due to bird size variation there are frequent mis-cuts, which can either give a long or short cut thigh or drumstick. The length of the thigh cut can have big impact on the nal thigh meat yield because it inuences the meat to bone ratio.

Foodmate OPTI TDC - Thigh and Drum Stick Cutter

The new Foodmate OPTI TDC - Thigh and Drum Stick Cutter provides a good and consistent joint cut. Furthermore the cutting angle of the blade leaves more drumstick meat with the thigh, which helps maximize both bone-in and boneless thigh meat yields. In addition to increased yield, also special attention was given to skin coverage. The machine provides a straight skin cut and covers the entire drumstick, thus increasing the amount of A grade drumsticks in tray pack operation. OPTI TDC

Foodmate focused on the entire process

OPTI-LTD whole leg, thigh

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Drum Bone Separation Station

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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

Leg Deboning and exible Dark Meat Deboning Solutions.

In the past whole leg deboning was a labor intensive and inefcient process. It either required a lot of skilled labor or the automation that was available was slow, capital intensive and had a high cost of ownership and low yields. Since the market for deboned dark meat is growing fast, there also is a need to be exible to supply various segments of the market with different boneless dark meat products. To do so, requires exible automation that does not require change over time or parts. Therefore, Foodmate deiced to develop a exible system that can be used to debone all variations of deboned dark meat such as deboned whole leg meat, thigh meat and drum stick meat.

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.

Foodmate OPTI-LTD Dark Meat Deboning System

Foodmates new OPTI-LTD Dark Meat Deboning System is a exible, total dark meat deboning solution that produces high-yield, superior quality meat efciently and

& drumstick deboner

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Thigh Meat Scraping Station

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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

Products that can be deboned at the OPTI-LTD deboner

Whole anatomic leg

Drumstick All products can be deboned with and without skin.

Anatomic thigh

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OPTI Thigh Deboner

Max yield & Perfect end product

High Yield and Hand-Cut Appearence
The Foodmate OPTI Thigh Deboner was developed to solve problems commonly found in both manual and automated thigh deboning operations. The unique concept and design of this machine will provide high meat quality and optimum yield, and only requires a few trimmers and inspectors. Unique Features and Benets of the OPTI Thigh Deboner: - Improves production speed with easy loading to handle 80 - 100 thighs per minute - Improves the ability to accommodate various sizes with the self-adjusting thigh deboner The innovative scraper design and tendon cutting system gives the meat a hand-cut appearance and does not shatter or crush the bones. Unlike other automated thigh deboners, the OPTI Thigh Deboner does not require a rubber disc to clean the bone, which signicantly reduces operating costs. There are many benets with the OPTI Thigh Deboner over hand deboning systems. Adding this feature will provide more consistent results, requires less operator training - Increases yield with minimal manual trimming needed - Eliminates bone shattering or fragmenting - Provides a hand-cut meat appearance - Reduces labor costs - Accommodates skin on or off thighs and more importantly, it does not create eronomic issues with your employees due to repetitive motion.

OPTI Thigh Deboner

Inline deskinning unit

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New cut-up modules

Foodmate is always on the move when it comes to improve and develop new cut-up equipment. Recently Foodmate introduced a number of upgrades and novelties on their cut-up lines.

New cut-up frames

The excisting frames have been changed a lot. In our R&D and engineering department our engineers looked very critical at several key-points on cut-up modules. We found that besides perfect cutting results the surrounding parts also needed attention and improvement, so we started on the frame design and functionality. - Hygiene: the existing frame structure allowed to give dirt and poultry parts to stick and stack on several frame positions. The result of that was that it gives a dirty look and that at a certain moment a pile of dirt or older product could fall onto areas where it was not planned. For that reason we studied and tested intensively on how we could reduce this problem, but still keep a good functionality of the machine, also construction stability couldnt make any concessions. The new frames are totally New cut-up frames free underneath and cutted product is allowed to make always a free drop. - Adjustments: plant a common people heard is: to

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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Foodmate eviscerating system

Foodmate offers a full line of high performance evisceration equipment. The capacities vary from low speed up to high speeds, without making concessions towards the bird quality. The Foodmate eviscerating line has been developed according the keep it simple principle. The machines are requiring a minimum a maintenance and are known for their low operation cost. The Foodmate eviscerating line can handle several bird types. Besides the above mentioned machines Foodmate can supply additional equipment and systems like gizzard processing and The Foodmate evisceration line consist of the following machines: Vent cutter Opening machine Eviscerator Pack releaser Cropping machine Neck breaker Inside & outside washer Final control waste material handling equipment. The Foodmate design makes it possible to adept the machine into lines supplied by other companies. The machines can be both executed in pipe and T- track overhead conveyor.

2000 800

300

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

OPTI-TD with Pirzola option

Pirzola & Thigh deboning machine in one

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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The Netherlands
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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.

Gebr. Heijs: combi retail/KFC cut-up line

The Heijs company is located in the North of The Netherlands and has become a key player in the fast food markets such as KFC. In 2010 Foodmate installed the rst KFC cut-up line in The Netherlands at the Heijs

Typical 8/9 piece chicken parts

9 piece fast food cut-up system

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Weighing/transfer system WTS

Foodmate has launched an all new weighing & transfer machine to her product range. This machine is a new top notch Foodmate product and ensures astonishing results. The all new WTS is designed to run at high speeds (12.000 bph +) and assures the best possible weighing accuracy (less than 10 grams up/down). Besides this Foodmate intended to develop a simple and reliable machine with a minimum of maintenance time and cost. Together with our partner on weighing, ChickSort from the United Kingdom we have the 1st machine running in a + 12.000 bph processing plant and is performing above imagination. The weighing system has the following functions: - Whole bird weighing/sizing - Whole bird batching - Bird counting The machine can be installed in several instance: - From airchill to distribution - Distribution to cut-up - Between 2 airchill lines in order to make a pre-selection on whole birds for wrapping - The WTS has a unique compact design and requires a minimum of oorspace congurations like for The system and set-up conguration is fully exible, please contact your local Foodmate sales representative for more information or contact Foodmate directly.

The most accurate whole bird weighing/transfer system available

WPG system
WPG system

Easy weigh-pack & go

Foodmate introduced a system that makes the packing and weighing of crates and carton boxes easier and more user friendly than on standard packing stations. Also the output per workers becomes signicantly higher. The WPG system is the perfect system for bulk production packaging. The WPG system is a packing system that weighs every box while the box is being loaded automatically and when the box is lled according the desired weight, a buffering hopper system stops loading the box. After this the operator can dispatch the box or crate and has the time to place a new box or crate on the scale deck/packing station, by one touch on the button the system will start loading again. The system is ideal on a central box or crate packing station. The stations can be supplied in several congurations, from a single station to multiple stations. The benets of this system is: - Better working conditions for the operators - Less operators required - Accurate weighing and packing - A simple, easy and reliable system that can be adapted in every type of operation

The simple and effective bulk packaging system

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New Digital machines manual @ Foodmate

Foodmate is introducing a revolutionary new user manual for selected Foodmate equipment. The new manuals are fully digital and are very user friendly. They can be used on PC, I-Pad and Android operated tablets. The digital manuals are showing an extremely good visible illustration of all parts that are used in your machines by just a click. The manuals are giving all essential information that you need to know and it makes ordering parts easier than ever. Also the manuals consist of a troubleshooting part. Another section has the possibility to organize a machine log book and report manager. Due to the fact that manuals have online accessibility, upgrades and updates can be integrated easily.

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