02 Dec 2021

Convenience Line Software: The key ingredient for consistency

Installing Marel’s software has made it easy for one of the world’s largest poultry processors to guarantee on-spec chicken nuggets – every time!

Convenience Line Software the key ingredient for consistent nuggets

As a supplier to one of the world’s largest quick-service restaurants, our customer knows just how vital it is to deliver highest quality products that meet specifications and all required food safety standards. Discover how Marel’s Convenience Line Software has become a crucial element in helping them achieve this by maintaining a consistent and controlled production process.

A consistent process requires consistent setup

Since installing Marel’s Convenience Line Software on their production line, our customer has had complete confidence from the outset that they are working from a consistent base. The software provides step-by-step guidance to their operators throughout line setup. It gives clear instructions on machines, settings and ingredients. This gives everyone a single source of direction so all operators work with exactly the same information and the possibility of incorrect line configuration is greatly reduced. Regardless of who sets up the line or when they do it, our customer is always sure that every detail is right – every time – and the same consistent starting point for processing is always achieved.

Convenience Line Software guides operators through line setup

Real-time feedback allows rapid intervention

Marel’s Convenience Line Software monitors the customer’s production in real-time and provides them with live dashboards to help their QC Manager see at-a-glance if product specs are being met. Before the software was installed at their plant, it was common to find out several hours after production that a batch of products hadn't met the correct customer specifications. And the opportunity to investigate and discover why was often long gone. Convenience Line Software makes it easy for the QC manager to see right away if there are any deviations from specs, and quickly intervene to keep quality and consistency on track.

It’s never been easier to keep product specs on track. The software gives us all the information we need to respond immediately and with certainty if something is going wrong.

Production Manager

A reliable QC process supports decision-making

Before installing software on their convenience line, our customer found that human error was a huge problem in the QC process. Quality control measurements were taken manually and not always with the greatest accuracy. The results were handwritten and paper records kept. Marel’s Convenience Line Software has fully digitized their QC process. Core temperature checks are now made with a Bluetooth thermometer, and all results feed automatically into a central database. The software also guides the QC technicians through the process to further minimize the risk of errors in reading and recording temperatures. Our customer knows the data collected is reliable, and can depend on it when making processing-related decisions. The QC data can access the data at the touch of a button if they should need it for QC evaluations, audits or recalls. It makes the entire process more accurate and considerably more reliable.

Convenience Line Software guides operators through QC measurements

Valuable insight helps optimize performance

To create convenience products of a consistently high quality, it’s vital to keep a line running optimally. Maintenance, operations and line operators have to work closely to identify and resolve any issues. Our customer found that this often proved complicated and ineffective. The Software now provides all the information their maintenance team needs to help quickly resolve issues on the production line. Dashboards with real-time performance data and alarm reports show clearly when the line isn’t running optimally and help to easily and reliably identify problems. And they have found that it isn’t always the equipment at fault. The software has changelogs that show whether an operator altered a program setting on one machine causing ripple effect throughout production.

The insight software gives allows us to act quickly and adjust equipment to immediately improve performance. We can also proactively find areas for improvement, which we couldn't do before.

Technical Development Manager

Reduce reliance on operators

Like many food processors, our customer has experienced difficulty in finding qualified people to operate their convenience line. The performance of the line and the quality of the products produced are heavily dependent on operator knowledge and skill. The software makes it possible to use less qualified staff, and at the same time it makes the role more attractive as it adds a smart element.

Convenience Line Software For Data-Driven Decision Making

Increase profitability with data-driven decision making

Having software on our convenience line has given us all the information we need to make data-driven processing decisions that help reduce giveaway, make better use of labor, optimize raw material use, and so much more. We know exactly what’s happening with regard to line performance, product specifications and order fulfillment and the reports the software generates make it easy for management to make high-level improvements that directly impact profitability.

The software makes it possible to compare the performance of different lines and even different plants. It also integrates effortlessly, not only with Marel equipment but also from other providers.

Pieter Klaas Hopma Zijlema,
Director of Prepared Foods, Marel

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