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
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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).
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