The first installation in the new line was the Filleting Machine MS 2730 which uses an automatic size adjustment feature to improve throughput and yield. With the ability to accurately fillet fish between 1.5 kg and 8 kg, the MS 2730 provided Camanchaca with the flexibility to process a wide range of fish species. Jorge Vergara González, Regional Manager of Salmones Camanchaca, remembers the introduction of the new technology as an adjustment but says today, "The results are really satisfactory. Our lines are approximately 15-20% faster than the industry average."
Soon to follow were two complete filleting lines: quality control system, desliming unit, filleting line, trimming, dynamic scales, portioner, pinbone remover and skinning unit, and secondary processing line.
More than 50% of the salmon Salmones Camanchaca processes is transformed into a large variety of fresh and frozen portions for the food service and retail markets. When choosing a portioning solution Salmones Camanchaca wanted a machine with flexibility and accuracy, the I-Cut 130 Portion Cutter was up to the task. "It allows us to make angled cuts and has a crucial precision in terms of weight and yield to maximize the efficiency of the portion in the fillet," says Vergara. The I-Cut 130 can make up to 1,000 cuts per minute and be easily programmed to various cut patterns, helping Salmones Camanchaca meet their current SKU requirements and ensuring adaptability for future demands.
Overweight packs are a thing of the past
The new customized packing line from Marel has reduced overweight giveaway in fillets by approximately 30% compared to the historical data from Salmones Camanchaca's previous packing line. The Custom Grader is fully integrated with automated conveyor belts, dynamic scales, barcode scanners and packaging stations, providing a seamless product flow. It reduces reliance on labor and improves line performance. As happy as Vergara is with the result of the whole packing line, he finds the Portion Grader the most exciting part. "It is a wonderful machine, one of the most interesting that I have had to implement. The overweight giveaway is over 60% lower and that has brought us great economic returns in the order of two to 2.5 million dollars [USD] a year."
In 2020 Salmones Camanchaca began implementing Marel’s software solutions into their primary and secondary processing lines. "Innova software has been fundamental to our digital transformation strategy. It has enabled us to capture data and perform real-time analysis of process information in both plants, primary and secondary," said Manuel Arriagada Ossa, General Manager of Salmones Camanchaca. Innova software enables operators to make real-time data-driven decisions to improve line efficiency. This ability to see and avoid problems quickly works in tandem with the advanced precision of the equipment to maximize processing efficiency and profitability.