Meeting market demands and adding value with Multihead Weighers

To get the most advanced technological solutions for its modernization, Ad’oro forged a partnership with Marel. The factory upgrade included a versatile batching solution with Marel Multihead Weighers for producing fresh-marinated and IQF products.
Marcio Lutfalla, Ad’oro’s Industrial Director, emphasizes that the company prioritizes equipment quality and its capacity to deliver consistently accurate and reliable results over the long term.

Accuracy is essential 

The decision to automate the manual batching operations was motivated by significant challenges in production. Marcio Lutfalla says, “The launch of our IQF product line required standardization, due to growing demand from the market for uniform fixed-weight products. This is especially critical for supermarket chains, where products on the shelf must be an accurate weight. As a result, batching automation became a necessity. With the introduction of the new Multihead Weighers, we prioritize precision and waste reduction, areas where Marel excels.

14 and 20-head weighers 

Besides automating the existing manual line for fresh-marinated products, Ad’oro also equipped the new IQF product line for frozen chicken cuts in one-kilo packs. The fresh-marinated product line features a 20-head Multihead Weigher Medium Fresh. The IQF line has one 14-head Multihead Weigher Medium IQF for smaller products, such as wings, tenderloins, and a 20-head Multihead Weigher Large IQF for products, such as breast and chicken thighs. The MHWs provide the optimal solution for producing fixed-weight batches with minimal giveaway and no weights below the specified target.

Two packaging formats

The marinated product line allows batching in various packaging formats using a single MHW, providing Ad’oro with enhanced production flexibility. This allows for two options: directing fixed-weight products directly to a packing machine for 1kg [2.2 lbs] packages or channeling the weigher’s output to a 700g [24.7 oz] Marel tray-filling system. Such precision wouldn’t have been possible batching by hand. So Ad’oro benefits not only from reduced labor costs but also from the increased rate of standardized fixed-weight products that meet market requirements.

Effective collaboration

Ad’oro opts for established brands, with Marel being one of its frequent choices. “We selected Marel for two primary reasons: our longstanding relationship and our trust in its capability to fulfill its commitments.” Marcio Lutfalla also highlights the positive experience of working with Marel’s engineering team, collaborating effectively with Ad’oro’s team. “With the marinade process we faced challenges which took longer than expected to resolve. However, the IQF process went smoothly, with fine-tuning completed within the expected timeframe.”

About Ad’oro

Ad’oro operates with three units, the processing and distribution center in Várzea Paulista, a feed factory in São Carlos and a modern hatchery in the city of Rio Claro. The company is a vertical integration, ranging from parent stock to final product distribution.

The processing plant in Várzea Paulista has a capacity of about 220,000 birds per day and also serves other processing facilities in Itapira and São Carlos. About 90% of sales are destined for the domestic market, focusing on the State of São Paulo. Ad’oro supplies retailers, butchers, supermarkets, restaurants, bakeries and industrial kitchens. 5% to 10% of the production is exported to Chile, South Africa, Hong Kong and some European countries. Chicken cuts represent about 95% of sales, whole chicken take up the remaining 5%. Ad’oro also offers a variety of processed products, such as sausages, seasoned, marinated, boneless and sliced.

Company site: adoro.com.br