Marel: The rise of vertical deboning systems
In this article, Marel explains the key benefits of hanging deboning systems, shed light on their significance for the industry, and discuss the current trends driving the adoption of this approach. Let's delve into the objective exploration of how vertical deboning systems are reshaping meat processing practices to meet the demands of modern production.
What is a vertical deboning system, what kind of processor is it for, and why?
As the name suggests, a vertical deboning system hangs pork carcasses from an overhead conveyor for processing. This method is particularly advantageous for, but not limited to, large pork producers or processors with a capacity of more than 400 carcasses per hour, as it can significantly increase efficiency, safety, and product quality.
By hanging the carcass, gravity assists in the deboning process, allowing for easier access to the meat (seam butchery), which results in more precise cuts and reduced wastage. Moreover, the automation of the process reduces manual labor and minimizes the risk of injuries.
Why is this better than traditional cutting and deboning methods?
Traditional deboning methods often involve manual labor, where workers physically cut and separate meat from bones on a table. This process can be labor-intensive and time-consuming, leading to inconsistencies in the meat quality.
The vertical deboning system in the DeboFlex is superior as it automates most of the processes, improving efficiency and safety and ensuring a more consistent and high-quality end product. Furthermore, it's more ergonomic for workers, reducing the risk of work-related injuries and increasing overall job satisfaction.
What makes the DeboFlex unique, and what is the return on investment?
The DeboFlex focuses on automation, efficiency, and traceability. It's a sophisticated, automated cutting and deboning system that delivers high-quality cuts while increasing yield. The system ensures precise and consistent cuts by utilizing advanced vision technology.
Our current DeboFlex customers have experienced up to a 40% reduction in labor—a substantial decrease in workforce and associated costs— and an increase of up to 3-4% in yield. These significant improvements lead to an average return on investment time of less than two years.
Its remarkable efficiency and subsequent savings swiftly offset the upfront costs. Profitability is significantly increased by reducing labor costs, maximizing yield, and ensuring consistent, high-quality cuts.
What are the current trends in pork cutting and deboning?
The pork cutting and deboning trends are moving towards automation and sustainable practices. While efficiency and safety are paramount, setting oneself apart from the competition is necessary in today's market.
If pork processors are contemplating replacing their cut-up and deboning solutions in the next 1-2 years, it's an opportune moment to consider a leap toward technology like Marel's DeboFlex. Investing in traditional technology might seem like the safer option, but it is shortsighted when we consider the industry’s future. Labor availability is predicted to decrease over the coming years, and sticking with labor-intensive traditional solutions doesn't future-proof your business.
Instead, taking a longer-term view and considering the efficiency, safety, consistency, and yield improvements that come with solutions like DeboFlex makes sense. Yes, the initial investment might be higher, but the reduction in labor requirement and increased productivity pay for that investment in less than two years. Investing in vertical deboning solutions like DeboFlex isn't just an option - it's a strategic decision to stay competitive and relevant in the future meat processing industry.
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