Why is the latest eviscerator technology crucial in a processing plant?

1. How can a modern eviscerator enhance efficiency beyond current levels?

The art of evisceration lies in consistently achieving high extraction performance across all broiler weights while also excelling in the giblet pack harvesting line. Mastering both aspects simultaneously is what makes the process complex. Modern eviscerators are data-driven to maintain consistently high performance with the least risk of human errors.

Such a system is better equipped to deliver consistent results, thereby enhancing efficiency. No matter the size, weight, dimension, or breed of chicken, a thoroughly clean carcass plus a rehung, immaculate viscera pack must be the result of the evisceration process at all times. This is only possible when the eviscerator flexibly tolerates variances in the set average flock characteristics but keeps performing optimally.

By automating machine adjustments based on real-time data, modern evisceration systems such as Marel’s Nuova-i optimize throughput and reduce the likelihood of human error, leading to improved operational efficiency.

2. Why is evisceration yield so important?

Evisceration yield refers to the amount of usable product extracted during the evisceration process. It is a critical figure because it directly impacts efficiency, profitability, and resource utilization. It involves maximizing the yield of packages extracted, ensuring top performance in extraction. Striving for the highest yield means less waste and obtaining maximum value from each carcass and giblet.

A high evisceration yield is important because it ensures high-quality organs and products, while at the same time effectively cleaning the carcass. Required for a high yield is therefore a perfect rehang (without product drops) and extraction performance, with a consistent, optimal performance of each individual evisceration unit, while minimizing losses and guaranteeing the highest possible quality of cleaned product and giblets.

3. What has the evisceration process to do with food safety?

Poor evisceration immediately impacts the final product's quality and safety. As evisceration deals with intestines, the risk of fecal contamination is always close. Proper evisceration ensures that the carcass remains free from contamination, particularly from intestinal contents. Such contamination due to misaligned evisceration would necessitate additional cleaning, trimming, or even discarding of carcasses, leading to yield losses and potential health hazards.

To guarantee food safety, the evisceration process requires high hygiene standards. The design of the spoon is crucial, as are the precise positioning and movements of the spoon inside the carcass to ensure the viscera pack is removed entirely—and nothing more, nothing less. The separation of the viscera pack must be an extremely clean process, resulting in a compact, intact pack with no intestines hanging out. This minimizes soiling and reduces the risk of cross-contamination. Additionally, no intestinal remnants should remain in the evisceration line to maintain hygiene and efficiency.

4. Why does the evisceration process need to be digital today?

You will see more and more HMI screens appear in the evisceration process. That’s because modern eviscerators are now highly automated, utilizing data-driven technologies to maintain consistent, precise performance with minimal human intervention. At capacities of 15,000 bph, mere human judgment doesn’t suffice anymore to make well-informed decisions. Therefore, the use of digital data capturing is indispensable to adjust the machine settings and monitor and assess the evisceration process. For instance, Nuova-i's performance monitoring detects exactly when an eviscerator unit is underperforming, even before human operators would notice. Addressing such issues promptly helps prevent yield loss or even line stops.

In addition to that, the machine performance itself is also subject to digital assessment. Intelligent internal software, such as Marel’s SmartBase, permanently monitors the machine's health status. In Marel's Nuova-i eviscerator, this means that SmartBase software evaluates the performance of each carousel unit in real-time, allowing for on-the-fly adjustments to optimize throughput and eliminate human error. Monitoring can even be done remotely, on a tablet or smartphone.
The data-driven core of the eviscerator allows for full digital programming of the process. Without needing too many technical skills, an operator can simply enter the ‘recipe’ that takes into account the weight and breed of the incoming flock of broilers. Previously, adjusting the machine for a different flock weight required precise intervention by skilled experts. Today, in the digital era, every operator can easily manage each flock. For heavier flocks, the appropriate program is selected on the touchscreen, and the machine settings adjust automatically. For lighter concept chickens, the corresponding program with the ideal settings for this product type can be chosen. This user-friendly system ensures simplicity and maintains incredibly stable performance.

5. Can a new eviscerator fit into any existing processing line?

Trouble-free incorporation of new technologies into existing processing lines is essential to avoid disruptions. Intelligent evisceration systems are designed with compatibility in mind, allowing for straightforward incorporation into current setups. This ensures that processors can upgrade their operations without significant overhauls. Marel’s Nuova-i is such a solution that integrates seamlessly into third-party evisceration lines. It accepts various types of shackles, thereby making it suitable for almost any processing plant in the world.

6. Isn’t the technology too advanced to train staff?

The implementation of any new technology always requires proper training. While the latest generation of eviscerators is designed to minimize manual intervention, operators are still essential for tasks such as controlling the machine's touchscreen, entering recipes, monitoring performance, and reviewing reports. As a result, both operators and maintenance personnel must thoroughly understand the new equipment. Marel offers a comprehensive training program for the Nuova-i to ensure staff can operate and maintain the system effectively, maximizing the benefits of the technology.