Marelec

Grading and batching

Grading and batching

The MARELEC Grading Solutions use state-of-the-art weighing technology and advanced software to design and build fully accurate

and fast graders. Building on its extensive experience, MARELEC offers grading solutions tailored to customers' specific needs. These can be used for entire birds or cut-up parts, fresh or frozen products. MARELEC graders can sort different sizes into fixed-weight trays or bulk packs. All equipment is built with robustness in mind and meets high standards of hygiene.

Compact grader

Grading Solutions

Compact means infeed, weighing and grading on one belt and in one frame. The MARELEC M3 compact grader is easy to use and is a simple and robust grading solution for sorting and/or batching of all kind of poultry parts. This is combined with the same precision of classic graders.

Key benefits

  • High accuracy
  • High weighing and grading speed
  • Robust and compact construction
  • User-friendly

With the MARELEC M3 compact grader, MARELEC sets the new standard for smaller versatile grading systems. It uses pull-arms for gentle handling and is available with 6 or 8 stations, combined left and right. Options such as batching are available on request. The compact grader with the 250 mm wide belt can be used for all kinds of poultry parts (fillets, wings, drums, etc.). The version with the 300 mm wide belt is used for grading whole birds. 

Specifications

  • Gates: 6 or 8
  • Belt width: 250 or 300 mm
  • Product weight: up to 5 kg
  • Max. product dimensions: Up to 290 x 400 mm
  • Maximum capacity: 120 pcs/min. 

Custom grader

Grading Solutions

The MARELEC Grading Solutions use state-of-the-art weighing technology for creating highly advanced accurate and fast graders. MARELEC has many years of experience and offers grading solutions that specifically suits the customer's needs. All equipment is built with robustness in mind and remarkably high standards of hygiene.

Key benefits

  • Intelligent Batching Algorithm
  • Modular concept
  • Hygienic design
  • Service
  • Flexible design

MARELEC has extensive experience in grading solutions. Each customer or situation is unique. With its solid background and experience in graders, MARELEC designs and manufactures a wide range of solutions for the specific needs of each customer. MARELEC places a priority on openness with customers, in order to identify needs and fulfil expectations. 

All grading systems consist of three important components:

  • Infeed:
    A correctly designed infeed system is crucial for obtaining the expected capacity of the grader. MARELEC offers a wide range of infeed systems. The perfect infeed system will be selected according to the application (type of poultry products) and requested capacity, ergonomics, and preliminary stages in the production process. 

  • Weighing:
    Poultry products are mostly weighed dynamically. Precision and speed are the most important elements of the weighing system. Product dimensions and weight determine the choice of the correct weighing part.

  • Sorting and/or batching:
    Marelec has a variety of solutions depending on the type of poultry products that need to be graded. The standard sorting systems are pull or push arm (flippers), retract conveyors and blow off. The sorting stations can be fully customized to customer's specific needs. These stations can be equipped with batching bins, presentation trays, tables, etc. Customized labels can be generated for each batch or tray by adding a label printer to the setup. 

One or more take-away conveyors can be optionally installed to transport the batches or trays to the next step in the production process. The grading systems can be connected to the MATRIX software, which allows full integration and traceability of the poultry products in the production

Grader after portioning

Grading Solutions

A grader after portioning will group different target weights together. MARELEC designs a variety of grader after portioning solutions that are suitable to the requirements of your poultry application.

Key benefits

  • Reduction in manual labor
  • Optimizes yield of the process
  • Configurable by customer
  • Feedback on weight to the portion cutter

The portion cutter PORTIO offers the possibility to cut to multiple target weights to optimize yield. Optional tools and an acceleration conveyor enable pieces to be separated after the cutting machine. 

A grader in line after the portion cutter will group the different target weights together. Optionally, batches can be created with these target weights. 

A grader in line with a PORTIO can consist of a wide range of designs. Customized solutions for special applications, e.g. trim tables, storage boxes etc. are designed according to the customer's specific needs. 

Turnkey solutions

Integrated solutions for Poultry

MARELEC has become a world respected player in integrating MARELEC grading and portioning solutions in complete wall-to-wall projects. Our hardware and software solutions can be integrated with third party solutions and can controll all of your secondary processing equipment.

Key benefits

  • Both hardware and software solutions
  • 40 years' experience
  • Custom designs
  • Robust and hygienic equipment
  • Third-party integrations

    Our field of expertise starts when products are dropped from the cut-up / deboning line and ends when products are packed, labelled, and palletized. Our own solutions can grade, batch, and portion your products. Intelligent trimlines are also part of our turnkey solutions.

    MARELEC Turnkey solutions can be integrated with all kinds of processing equipment, such as  X-ray machines, packaging equipment, labeling devices, etc.

    With the flexible and modular MATRIX Software, MARELEC offers total processing solutions adapted to the individual needs of the customer. This ranges from processing of production data and storage for reporting from a singular device to overall process monitoring and controlling the complete food processing plant. The order processing tool is designed for timely production of the exact order, with optimal yields and no give away. All products are tracked and traced throughout the entire process, right until the packages are labeled.

    Once a turnkey solution is sold, our team of project engineers manages the project from order until successful installation and hand over.

    We will be pleased to assist you with analyzing the total scope and goal of your project.

Whole bird grader

Custom grading solutions

Fast, accurate and gentle grading of whole birds (fresh, frozen or in bags). MARELEC can offer the best solution for your grading requirements. We grade into carton boxes, tubs, crates, or any other sort according to the customer's specifications. MATRIX software enables you to generate production reports.

Key benefits

  • Unparalleled accuracy
  • Optimum product handling
  • Ergonomic design
  • Robust and hygienic design
  • Various infeed systems
  • Customized weighing devices
  • Integrated in turn-key solutions
  • Easy connection with MATRIX software

    In many poultry slaughter houses, whole birds are graded according to their quality which will determine if the bird will be cut into parts or if it will be processed as a whole. In other processing facilities, whole birds are weighed dynamically. They are then sorted into tight weight ranges and batched into fixed weights or fixed-quantities per box. 

    The grader or sorter can be configured in many ways, such as the number of grading stations, or single, double, or triple lines with customized batching bins. MARELEC has built up a lot of knowledge and experience over the years to offer the perfect grading solution.

    Specifications

    • Belt width: 254 to 450 mm / 10 to 18 inches
    • Max. weight: up to 10 kg/ 20 lb
    • Lanes:1, 2 or 3
    • Multiple infeed systems
    • Various label printing and software options

Chicken parts grader

Custom grading solutions

Cut-up parts require accurate weighing and sorting at high speed. The unmatched weighing accuracy will enable you to sell your products at the right price and minimize give-away in trays or bulk packs. MATRIX software enables you to generate production reports.

Key benefits

  • Unparalleled accuracy
  • Optimum product handling
  • Ergonomic design
  • Robust and hygienic design
  • Various infeed systems
  • Customized weighing devices
  • Integrated in turn-key solutions
  • Easy connection with MATRIX software

  • Specifications

    • Belt width: 254mm / 10inches
    • Max. weight: up to 10 kg/ 20 lb
    • Lanes:1, 2 or 3

      In many poultry processing facilities, cut-up parts are weighed dynamically and sorted into tight weight ranges. Fillets, thighs, drum, or wings can be graded for a fixed-weight retail or bulk pack. Retail packs are graded to a fixed weight with minimal give-away and with a continuous focus on customer specifications. 

      The MARELEC intelligent batching algorithm provides the flexibility that processors need to fulfill tight customer specifications. For instance, retail packs or trays with minimum give away of a specific grade can be combined with a fixed quantity per pack. 

      The grader or sorter can be configured in many ways, such as the number of grading stations, or single, double, or triple lines with customized batching bins. MARELEC can offer you the right solution for each specific packing situation concerning packing into trays, boxes, or tubs.

Breast caps grader

Custom grading solutions

Breast caps or front halves are frequently graded to achieve higher yield in the next steps of the process. Naturally, it is only possible to sell breast caps at the right price when they are accurately weighed and sorted. Breast caps can be batched in crates, boxes, or tubs. MARELEC can offer you a single or multiple weigh deck solution with specific packing requirements.

Key benefits

  • Unparalleled accuracy
  • High capacity
  • Minimize human errors
  • Robust and hygenic design
  • Various infeed systems
  • Integrated in turn-key solutions
  • Easy connection with MATRIX software

Breast caps or front halves often fall directly from the cut-up line onto an infeed system that ensures proper feeding towards the dynamic weighing section. This infeed ensures the correct distance between 2 products to guarantee fast and accurate weighing.

Specifications

  • Belt width: 254 to 300 mm / 10 to 12 inches
  • Max. weight: up to 1,5 kg/ 3 lb
  • Lanes: single or double - horizontal or vertical
  • Multiple infeed systems
  • Various label printing and software options

Ergonomic design

A team of engineers translates breast cap sorting and packing requirements into a custom grading solution. Full consideration is always given to the ergonomics for the operators. This flexible approach guarantees the perfect solution for the application while maintaining the maximum throughput as a priority with the smallest possible footprint.

Robust and hygenic design

The graders have a completely open structure, without hidden corners, for ease of cleaning and disinfection. The design of the grader avoids horizontal surfaces. Batching stations can be opened easily. All electrics and electronics are contained in a completely sealed cabinets with a unique hygienic labyrinth double sealing. All materials used are FDA approved. To avoid housings and reductors, all motors are silent stainless steel drum motors with IP 66 or higher protection.

Various infeed systems

The  capacities will determine if a single or multiple sorting lane is needed.

Easy connection with MATRIX software

The interface is quick, user-friendly and intuitive to program. Over 100 programs can be stored. Production data can be viewed on the grader HMI. The user-friendly MATRIX program stores processing data on an office PC for traceability. MATRIX also allows the grader to be controlled remotely.

MARELEC Autodrop

Grading Solutions

The MARELEC Autodrop seamlessly delivers the batches produced by a grading system to a packing machine.

Key benefits

  • Small footprint
  • High capacity
  • No manual handling
  • Very hygienic solution
  • Seamless integration with other equipment
  • Configurable to the application

Once they have been delivered by a MARELEC grading system, the batches are tracked with our Matrix batch-tracking software. The MARELEC Autodrop can deliver up to 25 batches per minute into a packing machine (depending on batch size and product type) for placement into trays or vacuum packs. These can be tracked further into the process, so that the final package receives the correct QR- or barcode referring to the initial batch and primary products. This ensures full traceability throughout the process.

The Autodrop system can be configured to your precise needs, such as the size of your batches, or the packing configuration in your packing machine, etc. Technical specifications such as dimensions of the equipment and capacities are therefore subject to change.

MARELEC I Vision

Grading Solutions

The MARELEC I Vision camera is able to distinguish different poultry parts using artificial intelligence. It can be used together with a grader to automatically sort and weigh these parts.

Key benefits

  • Small footprint
  • Fast recognition time
  • Robust construction
  • High accuracy
  • Reduces labor

The MARELEC Intelligent Vision uses an intelligent algorithm to recognize different poultry parts. The MARELEC I Vision is equipped with a camera that takes a picture. The pre-programmed software compares this picture to the different species that are stored in a database. When the software matches the picture to the correct part, the right information can be sent to a grader or another system to select or sort the poultry parts.