Early grading leads to improved order handling

16 Mar 2015

IRIS moves up

Until recently the computer-controlled vision system for assessing product quality (Stork IRIS) would usually have been found in the pre-selection line immediately after chilling.
The NEW Stork IRIS system positioned in the evisceration line gives vital information on the quality aspects of each product allowing grading now to take place at the beginning of the in-line chilling process. You therefore have both considerable extra time and tens of thousands of graded products in the chilling process to achieve the perfect match with your customer’s purchase orders.

IRIS keeps an eye on every product. Plant yields and profitability can only benefit.

Grading before chilling

Valuable quality information up to three hours earlier

Many plants chill and mature products simultaneously in an in-line Stork maturation chill tunnel, as this is the best way of ensuring top quality, tender breast fillet products. Such a tunnel installed in a processing plant handling 13,500 broilers per hour (225 bpm) can hold up to three hours’ production or some 40,000 products.

An IRIS system installed at the end of the evisceration line can give management accurate information on incoming product quality up to three hours earlier than is currently usual. This will allow downstream production to be planned more efficiently, ensuring that each product is always put into its most profitable form and customer orders met as efficiently as possible.

The system will also allow effective remedial action to be taken if the quality profile of a given flock is different to expectations.

Better product presentation for more accurate grading

Each product locates into a positioning wheel driven by the overhead conveyor. This wheel pushes it outwards and ensures that its wings are perfectly presented with no risk of contact with its neighbor. Products are kept strictly separate, allowing both the whole product and its individual parts to be assessed with greater accuracy. Leg grading is better too as these are more visible to the IRIS system in a Marel Stork Poultry Processing evisceration line shackle.

More accurate grading means fewer misgrades, less rework, less lost yield and more profit.

Grades both wet and dry product equally well

IRIS moves up

Moving IRIS forward from the pre-selection line to the evisceration line has been made possible by the new system’s LED lighting and state-of-the-art recognition software. The system, which can assess both the front and the rear of the whole product and its seven individual portions, grades wet “reflecting” product just as accurately as it grades dry air chilled product.

All defects detected; red tails too

The system reliably picks up broken wings, red and blue bruises, fecal stains, residual feathers and skin damage. Two recent advances are the ability to identify red tails and “ignore” red wing tips. Previously, a red wing tip could cause the whole wing to be downgraded. Plants producing segmented wings discard wing tips. In such cases downgrading the whole wing creates unnecessary rework.

Quality information stays with each product

Quality information gathered by IRIS at the end of the evisceration line stays with each product on its way through chilling, pre-selection and cut-up lines.

This, together with weight information from a SmartWeigher installed in the pre-selection line, will determine its final destination in the whole product packing or cut-up and de-boning departments. Ultra-reliable Stork PDS-NT XL software keeps track of each product and its quality profile as it moves through the chill or maturation chill tunnel. The system even drops whole products selectively directly from the chilling line, based on this data.

IRIS in the killing and defeathering line

IRIS can also be installed in the killing and defeathering line to aid veterinary inspection and act as a quality check on growers. As the system uses color and shape to do its work, it will identify broilers which are damaged in some way, too small or have not bled out sufficiently. These can then be released automatically at the end of the killing line. The system also generates comprehensive reports on the quality of each flock, providing indisputable facts for any discussions with growers on quality issues.

IRIS an indispensable management tool

IRIS installed in the killing and evisceration lines is an invaluable tool giving plant management full information on the quality of product entering and leaving the primary process. This information can then be used to monitor grower performance, plan production more efficiently and react quickly and effectively to changing circumstances.