Salmon processor Hofseth invests in the new Deheader MS 3028 to improve the flow

Always looking towards innovations which will support their goals of providing healthy seafood without compromising people or the planet, in 2023, Norwegian processor Hofseth installed the Marel Filleting machine MS 2750. They knew it was the beginning of a new level of processing efficiency.

While the MS 2750 optimized the filleting process, for Kristina Kasperaviciene, Site Director at Hofseth, it also highlighted issues with their old deheading machine, including damage to the neck portion through poor cutting and line stoppages due to misfeeds. “Our old deheader was creating issues for the filleting machine,” said Kristina Kasperaviciene. Hofseth began looking for a new deheader that would improve cut quality and maximize the uptime of their salmon processing line.

The right size, in the right place, at the right time

To find the right option, Hofseth visited the Salmon ShowHow in Copenhagen. “We were looking at Marel machines that would fit in our old building, we don’t have much space,” said Arturas. By happy coincidence, this was the show we showed the prototype Deheader MS 3028, for salmon processors. Presenting it operation with a Marel filleting machine. “I saw that machine [Deheader MS 3028], and it was standing together with the filleting machine. It’s a very good size and it was what we actually needed,” Arturas Kasperavicius, Technical Manager at Hofseth remembers. Their interest piqued; Hofseth arranged a visit to the industry peers using the whitefish model, the precursor to the Deheader MS 3028. From these visits and conversations, the decision was made. And in early January 2025, Hofseth installed the first Deheader MS 3028 into their salmon processing line. Integrating it with the MS 2750 via an automated infeed.

Problems to solve

There were two main issues that Hofseth wanted the Deheader MS 3028 to address, stoppages and cut quality. The infeed between the old deheader and the filleting machine was manual. “We needed a person there just to flip the fish. And with human error, they could let the fish through in the wrong direction or force the fish through too fast. And then of course you stop the machine and the whole process line,” noted Arturas Kasperavicius. Line stoppages required the block to be cleared, machines to be cleaned and operators standing idle. With multiple stoppages every hour it slowed down the processing line and created unnecessary stress for all concerned.

Automating the infeed

An automatic infeed seamlessly connects the new Deheader MS 3028 and the MS 2750. Every fish arrives in the correct alignment to maximize filleting accuracy. By automating this task, Hofseth could move their operator to a new position and remove the element of human error that comes with repetitive tasks, dramatically increasing their uptime and production flow. A benefit seen from the very beginning. “We saw it in the first days; we had no stops.” Arturas Kasperavicius. However, he admits, he wasn’t onboard with this automation straight away.  “Before we had the first one, I wasn’t a fan of automating the infeed. I’d heard some other processors say they weren’t happy about the infeed, and I met others who were. So, there were a lot of different opinions, but when you see it all working together, the automatic infeed makes sense.”

When Kristina Kasperaviciene first saw the Deheader MS 3028 at the ShowHow, she knew it offered more than a way to improve production flow, “It is how it cuts the fish, the cut is much cleaner,” she remarked.

High value cut quality

The Deheader MS 3028 measures cuts from the eye of the fish to ensure maximize use of valuable raw material, while the three knife system cuts ensures salmon are deheaded cleanly, without tearing or peeling. Kristina Kasperaviciene noticed the difference immediately, “Basically we had no nice cut, it [the old machine] ripped off the head, affecting the quality of the first portion.” This damage during deheading reduced the value of end products and affected the efficiency of the filleting machine. “On the Deheader MS 3028 you get a straighter, cleaner cut.” With a clean cut comes less stoppages of the machine and less downgraded products, resulting in a higher packing yield.

Flexible with the same accuracy

By measuring cuts from the eye of the fish, the Deheader can maintain its accuracy when deheading different sizes of fish without having to adjust any equipment. “When we’re processing fish with variants between sizes of nose and thickness, measuring from the eye you don’t need to adjust the machine so much. That leads to much better flow through the filleting machine, because of the cut and because there is no human contact. It’s much more efficient,” said Arturas Kasperavicius.

Numbers are one thing; reliable quality is another

The Deheader MS 3028 has a throughput speed of up to 25 fish a minute and while Hofseth is sure the new deheader and MS 2750 combination will show increased yields over the coming months, Arturas and Kristina point out this was not Hofseth’s main goal. “The yield is just a small piece,” Arturas points out, “When you’re in production you need to think about the whole picture of the line.” Kristina agrees, adding, “Our goal was to eliminate that person in between and to get the line more stable. Improve the flow. Combined, the cleaner cut and automated infeed of the Deheader lead to much better flow and increase of higher-value cuts.”  

Shifting to the new machine

The introduction of new equipment on the production line will always mean an adjustment and learning period for operators. The plug-and-play, mechanical design of the Deheader MS 3028 keeps this learning curve as easy as possible. With minimal moving parts cleaning is faster and repairs more straightforward as providing low ownership costs to processors. “We see some operators get it very fast, just one or two days and they are already confident,” said Kristina Kasperaviciene.

About Hofseth

Established in 2002 Hofseth covers the entire value chain in the production of salmon and trout all within few hours in west Norway. With smolt facilities in Tafjord, farming in Storfjord, a harvest plant in Ålesund, and processing plants in Valderøya, Ålesund, and Syvde, they are working to be the world’s most sustainable seafood producer.