InsideTrack_IPPE2019_0219 InsideTrack_IPPE2019 - Page 10

SUCCESS STORY WHAT OUR CUSTOMERS ARE SAYING CUSTOMER Fieldale Farms · Murrayville, GA FOODMATE EQUIPMENT Four (4) ULTIMATE Whole Leg Deboners SCOPE Fieldale was asked by one of their key customers, to develop new dark meat deboning, marination and packaging process. To meet the requirements and quality set forth by the customer, Fieldale decided to expand their facility by 40,000 sf. Based on the success of the initial ULTIMATE Whole Leg Deboner, the plant decided to add three more systems, giving them a total of four high-speed ULTIMATE Whole Deboners. After whole leg is deboned on the ULTIMATE, the deboned dark meat is then marinated, bagged, weighed and placed in an in- line box-making process. The cases are then robotically stacked, palletized and wrapped with new state of the art equipment. OBJECTIVE Fieldale’s need to expand their leg deboning operation to accommodate their clients’ demands came with some challenges. With a tight labor market, it had ULTIMATE | A NEW STANDARD IS SET | been increasingly diff icult to meet their weekly production goals. Their primary WHOLE LEG DEBONING WITH SURGICAL PRECISION The ULTIMATE Whole Leg Deboner uses an x-ray measuring system to precisely measure each leg, using this data the machine automatically adjusts for each leg in real-time at a speed of 6,000 legs per hour. The x-ray allows the machine to cut at surgical precision around the knee joint, ULTIMATE leaving the kneecap attached to the bone ensuring very high yields and minimum labor during trimming. objectives were to reduce labor and increase yields. To achieve these goals, highly automated equipment was a necessity. Having had previous experiences collaborating with the Foodmate US team, Fieldale approached Foodmate when the Cornelia plant was looking at thigh deboning solutions. The success of the thigh deboners led to the order of three (3) OPTI Flow Cut-up Systems. So, when Fieldale started to look for an eff icient INTEGRATED J-CUT UNIT whole leg deboning strategy, it was only natural that Fieldale approached This specially designed unit makes a precise cut along the bone without damaging the meat or the bone; reducing stress on the bone during Foodmate for a solution, and Foodmate had the “ULTIMATE” answer! While still meat stripping, simplifying final inspection and allowing for good presentation. in its f inal stages of R&D, Foodmate installed the ULTIMATE Whole Leg Deboner at Fieldale’s Murrayville processing facility; they were the f irst plant ever to test the ULTIMATE. 9 9 Unmatched yields The testing period lasted about 12 weeks, and the results convinced the Fieldale 9 9 Minimal trimming team that the machine would be a signif icant improvement over their current process and help with their challenges in labor, quality, consistency, and yield. 9 9 Easy product loading After an extensive testing experience, the plant proceeded with the purchasing 9 9 Debones up to 6,000 legs per hour of the system, along with an additional three ULTIMATE Whole Leg Deboning Systems. The three other machines were installed once Fieldale’s planned 9 9 Integrated J-Cutting (leg incision) building expansion was completed, in August 2018. 9 9 Produces cartilage-free meat / with or without skin 9 9 Controlled by X-ray technology to adjust each leg in real time RESULTS 9 9 X-ray measurement system provides: Labor and yield improvements have both succeeded our expectations. Fieldale › Precise cutting › Kneeca6p › Individual sizing for each leg › Automatic shackle adjustment management was pleased to discover that their return on investment is exceeding all the goals. “We particularly like the x-ray and auto adjustment on Final Product shackle features, it is very unique, it gives the ability to treat each whole leg “The installation and commissioning of the four ULTIMATE Whole Leg Deboning Systems have been a huge success. We have been able to decrease labor by over 100 positions over two shifts. Additionally, we have been able to increase our pounds per man hour and our yield by 4% when compared to our old processes.” David Rackley Plant Manager, Fieldale Farms, Murrayville, GA individually, we had never been able to do that before with any system”, stated David Rackley, Plant Manager. “We made Fieldale’s challenge our challenge, and by collaborating with them to solving their problems and needs, we created a true partnership. We provided the technology and they provided the chicken and together we made this a very successful partnership!” Scott Hazenbroek, President & Founder, Foodmate US PAGE 10 Precise measurements for precise cuts From the left: David Rackley (Fieldale Murrayville Plant Manager), David McNeal (Foodmate Area Sales Manager), and Thomas (Hawk) Adams (Fieldale Murrayville Plant Engineer). PAGE 11