Haukur Hafsteinsson, embedded software engineer at Marel, explains how the road to making food proce..
Stork ACM-NT cut-up gains ground in China
02 Mar 2017
The challenge for mechanized cut-up is therefore to imitate the cuts done by hand as closely as possible. A perfect balance between an anatomical cut and traditional presentation is required. This is exactly what the Stork ACM-NT modular cut-up solution achieves in China.
In China, the need for automation is high, not only because of increasing capacities but mainly for reasons of food safety and human resources. To be able to industrially process the end products demanded by the market, Chinese processors need only pick the appropriate ACM-NT components from an extensive range of possible modules.
Wings, breasts and legs can be (anatomically) cut in various ways by several modules.
In addition to traditional Chinese food, fast food is making rapid progress in China. Quick service restaurants have a special need for products cut in a specific way. The KFC nine piece cut is a good example. Thanks to its flexible set-up, its consistently accurate high yield cuts and its operational reliability, the ACM-NT system can also meet these requirements.
Heading towards automation
Chinese processors have come to the conclusion that Marel Poultry systems are best for the specific characteristics of their market. Our solutions create end products which are completely in tune with the wishes of the Chinese consumer.
Automating the cut-up process using Marel Poultry’s latest ACM-NT processing technology is a good example of the direction in which Chinese poultry processing is heading. With its long-term commitment to the Chinese market, Marel Poultry is proud to support this development.
Second Joint Wing Cutter HY
Mechanically reproducing the Chinese manual cut
The latest addition to the wide variety of ACM-NT modules is the Second Joint Wing Cutter HY. In China, the center wing piece is a high quality end product, which is very popular with consumers.
In producing this typical Chinese product industrially, the Stork Second Joint Wing Cutter HY achieves both an accurate cut and perfect presentation while generating extra yield as well.
For a perfect Chinese second joint cut, it is very important that as much of the skin between first and second joints as possible is harvested along with the center wing piece.
At the same time, the cut should be fully anatomic, respecting Chinese tradition. Taking into account the expanding capacities in China, as well as human resources and food safety, manual cutting won’t suffice anymore and automation is the only answer.
Stork´s Second Joint Wing Cutter succeeds brilliantly in mechanically reproducing the movements of a skilled butcher, adding a large piece of skin from the first joint to the center wing piece. The result is a center wing piece which so closely matches the expectations of the Chinese customers, that virtually no differences can be identified between a manually cut and an industrially cut product.
Chinese processors choose ACM-NT
Marel Poultry has been chosen by the Hebei Luanping Huadu Food Company to completely upgrade its grading, cut-up and deboning lines. The Huadu management concluded that Marel Poultry’s systems adapt best to the Chinese market characteristics; the end products which result from our solutions perfectly meet the Chinese consumer’s wishes. Whole products, weighed by the Stork SmartWeigher in the 12,000 bph (200 bpm) distribution line, are allocated by weight grade to the Stork ACM-NT. The cut-up system ensures the highest possible yields while separating the various (anatomic) chicken parts. Finally, two Stork AMF-BX FlexControl lines debone breasts into breast fillet products.
Luanping Huadu also opted for the Anatomic Tarsal Joint Incision Pre-cutter, which cuts chicken feet – another important product in China – anatomically through the joint.
Supported by Marel Poultry, Binzhou will drastically expand its production facilities. The existing plant will be joined by an all-new factory. The Binzhou Gaosheng greenfield plant will feature two processing lines, each with a capacity of 13,500 bph (225 bpm). Stork’s ACM-NT modular cut-up solution will play an important part in both high-capacity processing lines and will cut products into ready to eat parts. The project will be a crucial stepping stone for the development of Marel Poultry’s position in China, as it is one of the first Chinese companies to automate cut-up and deboning at this scale and capacity.
The CP Dafa Chia Tai Beijing project includes a Stork scalding system, various pluckers and a selection line incorporating the SmartWeigher. PDS-NT software determines the optimum destination for every product. All data are stored to give full traceability, thereby allowing the company to adopt policies which ensure the highest food safety standards.
After quality selection, the Stork ACM-NT system produces a wide selection of high yield cuts. It includes a JLR anatomic leg cutting module, the industry reference for producing high yield anatomic legs.
Breast caps cut on the ACM-NT are deboned on two Stork AMF-BX FlexControl systems. Using less labor than any competitive set-up, the two systems produce a wide variety of top class, high yield fillet products with lower trimming losses at an average capacity of 7,200 breast caps per hour.
The latest project for the CP Group involves CP Jilin, a poultry processing facility in Yushu city, in the Chinese Jilin province. The Stork ACM-NT highcapacity cut-up line at the Jilin plant will feature the brand new Second Joint Wing Cutter HY, a module which has specifically been developed for the Chinese market.