News. Meat, Poultry and Seafood. Processors Invest in Automation Throughput to Increase by 14% Industrial Weighing & Product Inspection

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1 Meat, Poultry and Seafood Industrial Weighing & Product Inspection 22 News Processors Invest in Automation Throughput to Increase by 14% Changing retailer requirements, market growth and ever-increasing consumer requests for product diversity are placing more pressures on meat and poultry manufacturers. Enhancing productivity with improved weighing and inspection automation can help meat processors to differentiate and compete in challenging markets. A recent Food Engineering (FE) survey revealed that automation is thought by many processors to be one of the biggest trends that can lead to enhanced throughput. Overall, the outlook was optimistic with 71% of respondents believing that gross throughput at their location would increase by an average of 14% percent in the coming year compared to Automated systems are revamping how plants operate and how products are made. Until now, the meat and poultry industry has been slow to jump on the automation bandwagon. This is however changing, as new technologies emerge and processors look for ways to increase their throughput and satisfy the everchanging demands of consumers. Concerns and Industry challenges There has been a general concern among meat and poultry processors that automation may lead to a loss of process control and overall quality, affecting their ability to comply with stringent standards and regulations. In addition, manual processes and human skills such as butchery can be difficult to automate. The FE survey lists the following obstacles to productivity enhancement: Low Overall Equipment Effectiveness (OEE) Issues with process control and data collection Limited availability of factory floor space. There are different ways to overcome these obstacles.

2 Productivity & Automation Improvements Increasing OEE Reviewing processes and upgrading or installing new equipment can significantly improve overall line effectiveness. The latest weighing and inspection solutions contribute to overall product quality improvements and higher levels of equipment availability and performance. These are the key metrics used to calculate OEE. Optimizing manual processes Not all meat production processes can be automated, but optimizing manual processes through better data integration can help with throughput. Manual deboning with manual checkweighing is labor intensive and can lead to operator fatigue. Selecting a bench scale with smart data integration can be a first step towards a more automated process. ICS bench scales can store article-related data including product name or target weight in the scale s memory. With the help of an ergonomic workstation and increased data exchange, throughput can be improved by up to 25%. Automated weighing and Inspection Many plants have the scope to fully automate weighing and product inspection. Dynamic checkweighers can be integrated into processing and packing lines to weigh packaged product at high speeds. Out-of-specification products can be removed automatically without stopping the production line. Combination systems with integrated metal detection or x-ray inspection can also check for physical contaminants in a single inspection unit with minimal floor space requirements. Advanced data collection Improvements in automated process control can be achieved using advanced process monitoring and data collection software. ProdX Inspect, FreeWeigh.net and Collect+TM software packages from METTLER TOLEDO enable meat processors to further benefit from automation. Choosing the optimum weighing and inspection solutions can significantly improve process automation. METTLER TOLEDO can support in analyzing processes and selecting the right solutions to improve productivity and efficiency. Publisher / Production Mettler-Toledo GmbH Industrial Division Heuwinkelstrasse CH-8606 Nänikon Switzerland Subject to technical changes 09/2017 Mettler-Toledo GmbH New Industrial Weighing Catalog Find Your Required Solution with Our Full Product Portfolio 2 METTLER TOLEDO Meat, Poultry and Seafood News 22

3 Data Collection Software Boost Your Productivity Efficient Scale Data Management ICS scales can be connected via Ethernet, WLAN or USB. The powerful database can centrally be managed over a PC for an easy data exchange. Automated Inspection Data Collection ProdX Inspect software automates data collection from all product inspection equipment to improve process efficiency and enhance productivity. Improving production efficiency is vital to meat manufacturers. This comprehensive revision of the 16-chapter Food Productivity Guide brings you up-to-date ideas for process automation and cost optimization. Download the guide today: METTLER TOLEDO Meat, Poultry and Seafood News 22 3

4 Metal Detection Metal-Free and Fully Compliant Inspection Solutions Meet AA Standard A UK-based manufacturer of traditional English black pudding sausage in clipped-sleeve and natural-skin formats takes great pride in ensuring its products are of the highest standard and free from metal contamination. The company meets the BRC AA Standard by using advanced product inspection solutions. The sausage product is made using a family recipe that dates back more than 100 years, The Bury Black Pudding Company is committed to producing premium specialty products for domestic and international markets. Metal detection systems help the company maintain compliance with the strictest food safety standards and protect its reputation. METTLER TOLEDO Safeline metal detectors play a key role in the process, ensuring all products are free of metal contaminants. Maximizing efficiency The right inspection systems ensure that the company maximizes productivity. An HDS Pipeline system inspects clipped black and white pudding products prior to filling. A customized Profile Advantage conveyorized system inspects more challenging products including large pudding rings and frozen slices. Easy integration The company s first experience with METTLER TOLEDO equipment was an HDS metal detection system. Ease of use and integration with their existing Handtmann vacuum-filling machine were key drivers in the purchasing decision making process. The HDS system is sealed to IP69K as standard, making it suitable for the harshest meat processing environments. Superior performance Increasing demand for traditional black pudding rings required a new production line. Unlike clipped-sleeve products, the rings needed to be inspected at the end of the production line. The company also needed to inspect frozen products to meet export demands. A conveyor mounted Profile Advantage detector is used to inspect larger products where the product effect is a challenge. The nature of these products presents a challenge for metal detection due to a phenomenon known as the product 4 METTLER TOLEDO Meat, Poultry and Seafood News 22

5 We are impressed, says Richard Morris, Production Director. Product changeovers are quick, contaminant detection sensitivity is very high, and it s reliable and easy to use. The system s large pusher-style reject device, lockable reject bin, customized tunnel guards, and fail-safe confirmation sensors also ensure the company meets the codes of practice set out by the retailers it supplies. Overcoming the Product Effect SAFELINE Metal Detection White Paper effect. This effect occurs when products that are conductive or have variable temperature or high moisture content generate a product signal that the metal detector interprets as a metal contaminant, potentially leading to the rejection of good products. Multi-simultaneous frequency and product signal suppression technology built in to Profile Advantage detectors helps overcome these issues. Understanding Challenging Applications for Improved Metal Detection Contents 1. How a Metal Detector Works 1.1 Balanced Coil System 1.2 How Metal Affects the Balance Condition of the Metal Detector 1.3 Magnetic Fields, Conductivity, Permeability and Eddy Currents 2. Product Effect Explained 2.1 Factors that Influence Product Effect Moisture Content Temperature Size and Shape of the Products The Position and Orientation of the Product Through the Detector Consistency and Density of the Product Packaging Material 3. What is a 'Dry' Product? 4. Dealing With Product Effect 4.1 Low Versus High Frequency 4.2 Phase Discrimination 4.3 Multi-Simultaneous-Frequency Metal Detectors 5. Summary The product effect is a major challenge when inspecting meat products for metal contaminants. Find out more about overcoming the problem. Download the white paper: METTLER TOLEDO Meat, Poultry and Seafood News 22 5

6 Monitor Weighing Data Optimize Meat-Production Yield Monitor Efficiency from Anywhere When manually preparing meat, poultry or fish, efficient process control doesn t need to be complicated. An India-based poultry and fish producer invested in basic data collection and visualization software and now benefits from high product traceability, less waste, and optimized procedures. Last year, an India-based poultry and seafood producer installed METTLER TOLEDO ICS bench scales throughout three poultry production areas. By combining these scales with Collect+ data collection software, the company can monitor results on multiple dashboards, track operator efficiency, analyze yields, and improve product traceability. The system is delivering impressive results and providing guidance for further process optimization. Improve Traceability: Monitor Goods-In Versatile Material Dispensing Fast, Easy Quality Control In the entrance zone, all incoming chickens are weighed, controlled, and classified before being sent to the packaging zone. The dashboard for this area indicates: Product data Weighing results Incoming totals In the packaging zone, the chickens are prepared according to retailer specifications. The chickens are either wrapped completely or cut and portioned into trays. Operators can control and monitor: Overfilling amounts Average net filling Operator packaging speed Production managers monitor the results and obtain an overview of process efficiency in the goods entry or packaging zones. Yield analysis dashboards include: Operator efficiency Yield analysis Order fulfillment status 6 METTLER TOLEDO Meat, Poultry and Seafood News 22

7 Average Net Filling Incoming Totals Order Fulfilment Yield Analysis Collect+ Receive weighing data from all installed measuring devices in the goods entry or production zone Online results are refreshed every five seconds Publish and Share View results on any PC or mobile device Tailor your dashboard according to your needs Share the dashboard with colleagues Visualize Production output Production forecasts Worker efficiency Quality data Yield analysis Collect+ Monitors Work Efficiency Collect+ is a new data-collection software that captures weight and process data from every scale in production, including third-party weighing devices. Collect+ is updated every five seconds, providing both automated and manual production insights online. You can use this weighing data for quality initiatives, process optimization, and production control. METTLER TOLEDO Meat, Poultry and Seafood News 22 7

8 Checkweighing Performance Improved by 30% Higher Accuracy Under Extreme Conditions In times of increasing globalization, manufacturers in the meat and poultry sector are facing challenges in their production processes to reduce costs and increase efficiency. Dynamic checkweighers play a key role in addressing these demands. Automated Weighing Manufacturers increasingly see the value of replacing labor-intensive static spot-checks with automated, 100% inline quality inspection using dynamic checkweighers. This ensures Weights and Measures compliance and minimizes give-away. It also improves production efficiency, reduces labor needs and releases operator resources to focus on other production tasks. Checkweighers can play a leading role in cost reduction programs, especially if they have been designed to meet the strict requirements of manufacturers who operate within the meat and poultry sector. Full visibility of production data combined with high accuracy are key components required in these harsh and sometimes hazardous environments. Improved Performance The design of the new C-Series checkweighers from METTLER TOLEDO allows for much tighter tolerances at higher line C31 StandardLine Dependable accuracy for efficient in-process weighing. Configurable with 100 performance and productivity options. C33 PlusLine Robust performance and efficiency in demanding industrial environments. Over 200 performance and productivity options can be selected to meet specific application requirements. C35 AdvancedLine Precision and versatility for maximum efficiency in all production environments. Fully customizable with more than 250 performance and productivity options to address the most demanding applications. 8 METTLER TOLEDO Meat, Poultry and Seafood News 22

9 speeds. In many cases, production speed can be increased by more than 30% compared with existing systems on the market. Rapid set-up and simplified product changeover also contribute to process efficiency. At the same time, product-handling improvements remove out-of-specification products without stopping the line. Advanced Line Integration Integration is far more than simply having a solution that will fit into the space available. Connectivity solutions ensure that all production data can be collected. The C-series checkweighers are equipped as standard with an interface for all major industrial data protocols to support Industry 4.0 initiatives. Secure operator access and complete logs of all events support audit protocols. Feedback to filler software allows proactive fill level control. Thus the new C-series range does much more than just weigh. In a world where efficiency and profitability must be continually improved, deploying the most versatile and precise solutions gives manufacturers the competitive edge they need. Choosing the Right Solution See the full checkweigher product range and find out which solution is most suited to your application. Download the guide today: METTLER TOLEDO Meat, Poultry and Seafood News 22 9

10 Manual Recipe Weighing Stop Wasting Time and Ingredients Bring Certainty to Formulation Manual batch preparation must be fast and precise, as small deviations from predefined weighing tolerances can negatively influence consistency and taste. A new formulation scale makes the recipe weighing process easy, traceable, and efficient. The ICS689 has been enhanced with a new formulation functionality, making the terminal an efficient tool for manual dispensing applications. Software clearly guides an operator through a recipe and allows easy and traceable recipe weighing without costly networking infrastructure. Clear operator guidance The terminal can store 50 unique recipes, each with up to 50 different ingredients. By pressing just one button, the operator opens the recipe data library, selects the recipe, and starts the formulation process. The system guides the operator through the process by advising which ingredient to weigh next. Typically the system is configured to accept the proposed ingredient by confirming and pressing a soft key on the terminal. Once the recipe has been NEW completed, the operator confirms the end of the process and the batch data is stored in the terminal memory database. Reduced waste A graphical bar on the screen gives clear feedback on the actual dispensing status. In case an operator adds too much of a single ingredient, the system can recalculate the amount of other ingredi- Soft Keys for User Guidance The scale offers different visuals and soft keys for clear user guidance. The operator starts the process by pressing the formulation soft key to access the recipe database. Fast Filling Preferred A color bar graph indicates filling status. Green means the operator has reached the pre-defined tolerance range and can continue with the next ingredient. Less Waste If too much of one ingredient is added, the operator can simply press a key. The software automatically recalculates the recipe and guides the operator through adjusting the other ingredients to save the batch. 10 METTLER TOLEDO Meat, Poultry and Seafood News 22

11 ents required to let the operator adjust the recipe. Choosing a scale with an appropriate weighing range further reduces waste. If required, ICS689 terminals also allow up to four platforms to be attached. By simply pressing a button, the operator can shift from bulk to fine ingredient weighing. This speeds up batching and reduces waste. Safety and traceability Material data and batch numbers can be entered for each ingredient. When working with a barcode reader, the system can be configured to reject ingredients with the wrong barcode. It can also stop the process any time a weight is outside the acceptable range. All recipe changes or manual overrides are tracked in the database, and details of each mix can be output to a printer, memory stick, or PC for archival records. Flexible and mobile All ICS6-series bench scale models can be equipped with WLAN technology. In combination with an optional builtin rechargeable battery, these scales can easily be moved and placed where they best fit into your production operations for fast, safe formulation that meets your recipe requirements. ICS689 Formulation Terminal The ICS Formulation features are: Storage of 50 recipes 50 ingredients per recipe Overfill correction functions Horizontal or vertical batching Terminal facts: Color TFT display Scratch-resistant keypad IP69k protection Four attachable platforms METTLER TOLEDO Meat, Poultry and Seafood News 22 11

12 Calibration and Validation Are You Compliant with the Latest ISO Revision? New Industrial Weighing Catalog Free Download Recent changes to standards and ISO regulations have again increased the requirements placed on food manufacturers. Two new webinars help meat manufacturers optimize service visits and comply with the latest regulations. Seven Easy Ways Service Reduces the Risks of Non-Compliance This new webinar details the seven service elements that make it easier for food manufacturers to comply with the latest food safety standards and regulations. Reduce Calibration Costs with Risk-Based Analysis This 15-minute webinar details how an ISO certified company can optimize calibration efforts based on the latest ISO 9001 revision by mounting a risk-based analysis For more information Mettler-Toledo, LLC 1900 Polaris Parkway Columbus, OH Mettler-Toledo Hi-Speed 5 Barr Road Ithaca, NY Mettler-Toledo Safeline 6005 Benjamin Road Tampa, FL Mettler-Toledo CI-Vision 2640 White Oak Circle, Unit A Aurora, IL Mettler-Toledo, Inc Argentia Road, Unit 6 Mississauga, Ontario L5N 8G6 Local contact: Document No