Data-driven adaptive chicken breast deboning

Processors are looking for an automated deboning solution that creates maximum value from their raw material, fulfills orders precisely to individual customer specifications and uses the least amount of labor. ATHENA meets all these criteria.

Less labor

Finding operators for a poultry processing line is currently a global issue. That’s why Marel has developed a system needing only two operators despite its high capacity of up to 6,000 chicken breasts per hour. Right at the start of the process, these operators put every breast into the loader, an ergonomically convenient and easy operation with no force needed. It’s the automated loading system that puts the breast onto the product carrier.

No more touching

ATHENA‘s biggest step in saving labor is the automated fillet harvesting process. It uses diabolos to effectively ‘unroll’ the fillet from the carcass. This approach carefully positions fillets onto a conveyor for singulated presentation to a downstream process. Manual singulation is no longer needed for weighing, vision grading, inspection and portioning. Overall, ATHENA’s data-driven deboning drastically reduces the need for trimming.

Weight range

Today, consumers are more critical about the kind of chicken they eat. They ask for specific characteristics, like a free-range or concept chicken. Marel’s ATHENA system can handle a wide variety of chicken breeds with their different shapes and weights. Breast weights from 300 to 1500 grams can be processed without any problem. No manual adjustments are needed when big chicken breasts are fed to the ATHENA. The measurement module at the start of the process sends its data to the rest of the modules. These will then set themselves to handle each individual breast, minimizing the need for trimming afterwards.

Remotely changing recipes

With fewer staff available to the plant, it’s convenient that ATHENA doesn’t need adjusting during operation. The system doesn’t have any external hand wheels, levers or other mechanical tools. All settings are automatic or electronic. Via the HMI screen, or even more easily, wireless via a remote device, it is possible, for example, to change recipes or product type. With a press on the touchscreen, the recipe changes from regular broiler to concept chicken. All modules will adjust themselves and deliver the required end products to specification.

Connectivity

Marel’s ATHENA makes life easier in the processing plant. It collects data and tracks product through the process. Using this data, ATHENA’s integrated software gives realtime insight into line occupancy, loader efficiency and the machine’s general health status. It also monitors performance per product carrier in terms of product loss, successfully completed deboning steps, carrier damage and more. The standard integrated software in ATHENA is not limited to just the machine. Thanks to a maximum-security internet connection, it really ‘connects’ the deboning line, offering remote monitoring. Anywhere in the world, the plant manager’s mobile phone can display ATHENA’s deboning figures. In addition, Marel can help solve issues remotely, if asked by the processor.

Downstream delivery

The intelligent machine-to-machine communication of Marel solutions enables ATHENA to link to upstream and downstream processes. Not only the product is conveyed but also its data (Digital Product Transport). Once a fillet has been harvested and put on the belt, data on flock, recipe, end product destination stays with the fillet. This data passes automatically to downstream processes. Sensors along the conveyor belt keep track of passing fillets. This is an optimum way of supplying product and data to Marel’s downstream Fillet Value Optimization solution.

 End products

Marel’s ATHENA system will create any end product required by the customer: butterflies and fillets, with or without tenderloins, tenderloins with or without tendon and more. The system’s flexibility allows mixed production at individual fillet level. What could be more agile than having one product carrier release a fillet with tenderloin and its neighbor one without tenderloin?