The installation of a complete Marel minced meat plant with total recipe control was instrumental in the ongoing optimization of Dafgård’s extensive and varied production of oven-ready food for restaurants, catering centers and supermarkets. The amount of pure meat processed per day more than doubled in the first six months of the running-in period.
Two Marel fat analyzers were integrated into the preparation lines for fresh and frozen meat respectively. Department manager Christoffer Sundberg and project manager Håkan Andersson agree that at Dafgårds, online fat analysis equals good economic results.
The fat analysis system is a great asset to our production. Control and standardization of each batch of meat are immensely important as our customers request homogenous products., Håkan Andersson, Project Manager - Dafgårds
The accuracy of the system allows us to add more fat than before without exceeding the fat content specified for the end product. So everyone benefits. Our customers get high-quality products and we save expense” says Andersson.
Andersson stresses the fact that the system is user-friendly. “Apart from being highly accurate, the fat analysis system is simple to use and easily programmed. Our operators have had no problems whatsoever working with the displays,” he says.
He adds that the fat analysis unit, along with all other processes in the plant, is controlled from their main computer system. For the entire plant, this automation means a reduction in staff of approximately six people per shift compared to their older, manually controlled mixing line.
“Before we purchased our new plant we had way too many operators. Additionally, we experienced problems with cycle times that were too long and lacked capacity. Due to the microwave defrosting on our line for frozen meat, we have achieved considerable capacity improvement through cycle time reduction. What took us three
days before, now takes us half an hour. This has made us more flexible in the sense that we can respond quickly to the needs of our customers,” Sundberg says.
Today’s consumers are very concerned with food safety and are demanding accurate and targeted traceability information on the products they buy. At Dafgårds, active and continuous measures are taken to ensure that safety and quality standards are in place.
Christoffer Sundberg adds that “The recipe control system from Marel provides us with complete control of each batch and full traceability of products. Each batch is easily identified, and its process of production tracked and verified.
Sundberg likes to point out the fact that food safety also depends on the hygienic standards of processing equipment. “Marel equipment is easy to clean, and the surface finish prevents the meat from being held up in the equipment. We haven’t had problems with accumulation in the machines affecting product quality when rejoining the main product flow,” Sundberg says.
Dafgårds chose Marel because of a technically superior solution. Sundberg does not hesitate to say that the equipment is outstanding and that Marel possesses valuable technical knowledge. “We are very pleased with the efficiency of the plant. We can produce much more than before and have full control of all products in the production area” he concludes.