Precision in every poultry portion

JBT Marel is a leader in this field. You can find integrated JBT Marel solutions that help get the most value from every piece of whole muscle meat. At the heart of such processing lines are two sophisticated, but different portioning methods: waterjet cutting and blade cutting. It is important to choose the right technology for each production goal. In some cases, blade cutting works best; in other cases, waterjet portioning is needed.

Flexible waterjet cutting

In situations that ask for ultimate flexibility and maximum yield from every piece of meat, waterjet portioning is the technology of choice. Waterjet portioning is required when dealing with highly variable raw material or when creating fat-free, fixed-weight products with minimized giveaway. By scanning the size, shape, and thickness of each individual fillet, a waterjet cutter can calculate and execute complex, curved cuts to create perfect fixed-weight portions. This is something a straight blade cannot do. When incoming customer orders ask for uniquely shaped products with trimmed-away fat and near-zero waste, waterjet portioning is the premier choice. 

If you can draw it…

The idea is simple: if you can draw the shape, the DSI 800 Series Waterjet Portioner can cut it. First, each piece of meat is scanned and even fat deposits are detected. Dedicated software then decides how to cut that piece to create the highest-value products. High-pressure waterjets cut the meat into the planned shapes. This can include trimming fat and cutting sized fillet, strip or cube portions in one go.
This system is very efficient. You can create products that meet special customer requests. There is almost no waste because every part of the meat is turned into a valuable product, reducing giveaway and increasing profits. Water use is no more than 60 liters per hour.

Fast and efficient blade cutting

For high-volume production where speed, throughput, and consistency of uniform cuts are the top priorities, blade cutting is the ideal solution. When you need to produce thousands of identical chicken strips, cubes, or sized fillets with standard cuts for a fast-food chain or large food service contract, blade cutters excel at this. They use high-speed knives to make clean, straight cuts with unmatched efficiency. They are the workhorses of the portioning world, designed to process large quantities of product quickly and reliably, making them perfect for creating standardized products at maximum capacity. Integrated in a Strips and Sandwiches Portioning Line or a Cubing Line, blade cutters are dedicated to a certain end product, producing sized fillets, strips or cubes, validated by QSR chains.

An outstanding blade portioner is the dual-lane I-Cut 122 TrimSort. It lets you run two different programs at once on the same machine. For example, one lane can cut sandwich fillets while the other makes strips. Using a return belt, one lane can cut strips that are then fed back to the other lane to be cut into cubes. The machine also sorts the main product and the trim automatically, so there is no need for manual sorting later. With user-friendly software, processors can store recipes and keep results consistent, even when spread over time for multiple orders.

Integrated instead of separate

What makes JBT Marel’s portioning solutions special is the full integration around the cutting systems. The different machines in the line can communicate with each other. They share feedback and suggest the best portioning approach based on calculations. For best results, an integrated portioning line can include:

• Robotic positioning: The RoboOptimizer places meat correctly on the belt, removes overlapping pieces, and keeps the process smooth.
• Product preparation: Splitting systems before the portioner can horizontally split large fillets, so that all products have the same thickness for better ‘3D’ cutting.
• Sorting: once products are portioned, they have to be sorted. For example, the offcuts must go to a different destination than the main products. Several JBT Marel sorting solutions are available, including the integrated TrimSort in the I-Cut 122.
• Central software control: JBT Marel’s Portioning Software controls the whole line. It shows a clear overview, lets operators adjust settings, and tracks real-time data on yield and speed. It also contributes to the full traceability from raw meat to packed product.

Conclusion

JBT Marel offers you a powerful way to handle any portioning need. Whether you want flexible waterjet cutting or fast blade cutting, these integrated solutions help you deliver high-quality, consistent products. By combining advanced machines with robotics and smart software, JBT Marel enables you to stay competitive and profitable in today’s market.