Foodmate Equipment (3) OPTiX Thigh Deboners (2) OPTI Flow Cut-up Systems (2) Leg Processors Scope Foodmate has replaced the plant’s hand thigh deboning lines with 3 OPTiX Thigh Deboners. The main goal was to deliver labor reduction and meet or exceed yields. For this to happen, our team’s goal was to provide a solution that improved the thigh deboning process’ performance and increased the number of thighs with the oyster attached.     FOODMATE STRATEGY Our team analyzed the plant’s needs and developed a solution that addressed the main goal: maintain or increase yield and ..read more

Foodmate Equipment   (2) MAX6000 Breast Deboners (1) OPTI Flow Cut-up System Scope This project comprised a total rebuild, which went from a big bird deboning production to running products exclusively for a leading fast-food chain that focuses on a high-quality product. The main goal was to produce a high-quality product while keeping labor costs at a minimum. FOODMATE STRATEGY The Case Farms project encompassed a total product-mix change and revamp for the plant. Foodmate advised on the best layout and solution to achieve the required high-grade product. Two MAX Breast Deboner ..read more

Foodmate Equipment Poultry grading, distribution and OPTI Flow Cut-up System drip line out of the chiller to a weight transfer system to distribution line with vision grading. Three (3) buffer transfer machines to three (3) retail frame cut up lines, multiple WOG drops and one 8/9 piece cut up line. Scope The scope of the project was to provide grading and cut-up for 220 birds per min out of the chiller. From the chiller, the birds are introduced to a distribution line where the birds are weighed and graded and then distributed to the appropriate WOG drops or cut up lines based on weight ..read more

Foodmate Equipment Three (3) new Foodmate OPTI Flow Cut-up Systems on 10”centers including ChickSort 3.0 weighing and vision grading software. Scope The scope of the project was to provide a new cut-up solution for the plant’s tray pack operation and to be able to process 280 birds a minute while utilizing the least amount of space. The product mix includes A-grade bag birds, whole wings, sizing of fronts for automated de-boning, split breast, leg quarters, whole legs and drum and thighs. Fieldale was asked to develop a new process for their customer; so they added an additional 75,000 s ..read more

Foodmate Equipment Eighteen (18) OPTI Thigh Deboners with Kneecap Separator (KCS) will receive the upgrade Scope & Foodmate Strategy The scope of this project was to upgrade every Foodmate OPTI Thigh Deboner with a Kneecap Separator (KCS) within the Pilgrims organization. Before installation of the KCS’s, each plant was visited to minimize or eradicate any potential issues during the install. Once the teams were comfortable with back- end planning, it was decided to installation of the KCS units take place over the weekend, minimizing downtime. OBJECTIVE To reduce staffing at the tri ..read more

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 ..read more

Foodmate Equipment (1) MAX6000 Breast Deboner Scope Allen Harim’s plant in Millsboro had two lines at 105 birds per line each, and needed to debone 210 birds/ min, therefore the decision was made to move from cone lines to auto-deboning. With the increasingly difficult labor challenge, deboning automation seemed the logical option for this client. OBJECTIVE Due to the summer season and their proximity to the Atlantic beaches, Allen Harim experiences massive labor shortages from May through September, resulting in up to 40% absenteeism daily. The company’s objective was break the cycle by ..read more

Foodmate Equipment (2) MAX6000 Breast Deboners Scope The scope of the project was to remove two existing breast cap filleting systems and replace them with two Foodmate MAX 6000 Whole Breast Deboners. Plant production is around 650,000 birds per week, about 70-80% of which is deboned, depending on orders. OBJECTIVE & Strategy Foodmate’s goal was to provide a solution that would improve the plant’s throughput, quality of end-product, and reduce the cost of ownership of automated breast debone. Having completed other large projects with Gerber’s, Foodmate has established a good partner ..read more

Foodmate Equipment One (1) ULTiMATE Whole Leg Deboner Scope Hain Pure Protein needed a whole leg deboning solution, their major issue was the ongoing labor challenge, automation became a necessity. OBJECTIVE Hain Pure Protein was using a competitor’s whole leg deboning solution, running at 60 legs per minute and was taking 40 people to do run it. Their yields was in the low 50’s and they were sending about 120,000 lbs a week out to contract deboners to debone the legs. That was not an ideal scenario, their objective was to stop their deboning outsourcing by increasing their in-house deb ..read more

Foodmate Equipment Three (3) MAX6000 Breast Deboners Scope Fieldale at Murrayville used auto deboning and cone lines. The plant processes 420 birds a minute and needed to reduce labor and debone front halves. They also required less rework and higher quality breast and tender. FOODMATE STRATEGY Foodmate brought a test machine to Fieldale, so their team could run tests with their product and assess if the machine was a good fit. After extensive testing, the Fieldale team found that the MAX delivered a consistent 3% increase in yield comparing to the previous equipment. This increase w ..read more