ULTIMATE , WHOLE LEG DEBONING WITH SURGICAL PRECISION
This machine is a total game changer when it comes to whole leg deboning technology . The ULTIMATE measures each leg and makes precise cuts based on the feedback it gets from the X-ray unit .
That ’ s right , the guessing game is OVER !
Exceptional yields . No bones about it .
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CUSTOMER Fieldale Farms
FOODMATE EQUIPMENT
ULTIMATE
SCOPE
Equipment Testing
“ We want to thank Fieldale for their trust and support and the business they have awarded us .”
SCOTT HAZENBROEK
Success story what our customers are saying
FOODMATE ULTIMATE END RESULTS
Fieldale Farms is a family business , still owned by its founders , but has grown to become one of the largest independent poultry producers in the world . The Murrayville plant operates two shifts and produces around 1 million pounds of boneless leg meat per week for its customer Chipotle .
Last year during IPPE 2017 , Foodmate and Fieldale started conversations about their plans to expand the leg deboning operation and how it is becoming increasingly difficult to meet their weekly production goals due to the tight labor market . Therefore , as part of Fieldale ’ s expansion plans to help overcome labor issues was to find new technology and suitable automation to help improve yields .
“ Last year during IPPE 2017 , Foodmate owner , Scott Hazenbroek showed us a video of the prototype whole leg deboner they were working on and it showed a lot of promise . We told Scott if Foodmate had the need of a test location , we would be happy to work with Foodmate and offered the Murrayville plant as a testing facility .” - said David Rackley , Plant Manager , Murrayville Complex .
Based on that invitation , Foodmate installed the ULTIMATE Whole Leg Deboner in November 2017 and started testing and fine tuning the machine . After two weeks of getting the machine dialed in , Fieldale started running the machine in full production during two shifts and 5 to 6 days a week .
“ Bringing the machine into a test location where they actually run four leg deboning lines was a great opportunity for us to compare our results against Fieldale ’ s current process and to learn more about the ULTIMATE ’ s performance and technical aspects . In addition , we were able to get great feedback from David and his team so that we could incorporate any potential design changes they suggested .” - said Scott Hazenbroek .
For a new and unproven machine in a US production facility , the installation has gone well with no substantial technical issues that have presented itself since the machine has been running .
Fieldale ’ s main goal for the new equipment is to reduce labor and improve yields and after running the machine since November , Fieldale is very confident that the machine is a big improvement over their current process and it will help them with their challenges . This success has led to the decision of purchasing the machine used in the testing as well as 3 additional machines , all to be installed once Fieldale ’ s planned building expansion is completed in August .
“ It was a very easy decision to make , the equipment appears to be extremely reliable and despite the fact that it uses cutting edge technology such as the X-Ray Measuring System , it is a simple machine to operate and maintain . The most important thing is to keep the blades sharp . We attribute the consistent results and high yields to the X-Ray Measuring System . Previous technology always required to find the best middle of the road setting , was labor intensive and required skilled people to operate . The ULTIMATE measures each leg and makes precise cuts based on the feedback it gets from the X-ray unit . This machine is a total game changer when it comes to whole leg deboning technology . Scrape tests are showing an average improvement of 33 grams per whole leg compared to our current process and we fully expect to have staff headcount reduction by 100 once the new machines are installed .” - stated David Rackley .
Foodmate ’ s relationship with Fieldale started when the Cornelia plant started looking at thigh deboning solutions . This was the beginning of what has become a fruitful relationship for both companies . The success of the thigh deboners has led to the order of 3 OPTI Flow Cut-up Systems , and now , the purchase of 4 ULTIMATE Whole Leg Deboning Systems .