Poultry processing

OPTI LTD | Exceptional Yields and Flexibility

Whole Leg Deboning and Flexible Dark Meat Deboning Solutions

In the past whole leg, thigh and drumstick deboning, was a labor intensive and inefficient process. It either required a lot of skilled labor or the automation that was available was slow, capital intensive and had a high cost of ownership and low yields due to rework.

Since the market for deboned dark meat is growing fast, there also is a need to be flexible to supply various segments of the market with different boneless dark meat products. To do so, requires flexible automation that does not require change over time or parts. Therefore, Foodmate decided to develop a flexible system that can be used to debone all variations of dark meat such as whole leg meat, thigh meat and drumstick meat.

Foodmate OPTI LTD Dark Meat Deboning System

Foodmate’s new OPTI LTD Dark Meat Deboning System is a flexible, total dark meat deboning solution that produces high-yield, superior quality meat efficiently and cost effectively.

Capable of deboning 100 skinless or skin-on anatomical whole legs, thighs and drumsticks per minute, this system is so flexible that no additional parts or changes are required when switching between the various dark meat products.

NEW! Automated J-Cutting Station

In addition, the new system now has an added automated J-Cutting Station, which makes a

pre-cut along the drumstick bone, knee joint and thigh bone.

Key Benefits:

• Excellent yields
• Low cost of ownership
• High output per operator
• Optional Knee-Cap Remover
• Designed to debone any size bird
• Optional Automated J-Cutting Station
• Minimal bone content - less trimming required
• Capable of meeting all boneless leg meat specifications
• Debones 100 whole legs, thighs or drumsticks per minute
• Simple all-mechanical design, user friendly and easy to maintain
• Can process left, right or both legs depending on chosen configuration

https://www.youtube.com/watch?list=PLuZN06P3cFFHSuntXNR-0WECNXO5Fa9nX&v=AgH-hulf2YU

Foodmate Flex Cut-up System is one of the market’s most advanced cut-up systems, offering excellent efficiency and flexibility. The system combines the advantages of the optimal solution for whole bird distribution based on grade and weight as well the optimal logistic solution to deliver parts to any desired location in the cut up area.

Modules can be customized according to your plants’ requirements.

The Flex Cut-up System can distribute birds by weight and/or grade to all the necessary WOG (without giblets) drops or cutting modules; as it pairs with Foodmate | ChickSort Weighing Transfer Machine and InVISION Camera Grading System.

Typical Set up includes:

Tail Cutter

Wing Stretcher

Wing Tip Cutter

Mid Wing Cutter

Super Wingtip Cutter

Halving Machine

Halving 2 Machine

Breast Processor

Saddle Cutter

Saddle Cutter 2

OPTI XL Leg Processor

Thigh Drumstick Cutter

Flexible Unloader

https://www.youtube.com/watch?v=6hApa2LRnkw

The Foodmate Food Service Cut-Up System is designed to meet all 8-piece, 9-piece and dark meat cut-up requirements.

A typical 8- and 9-piece machine consists of a tail cutter, foodservice wing cutter, inline fat puller, pre-cut and or keel cut. For a 9-piece cut, it includes the lengthwise halving machine, thigh popper, foodservice halving machine, food service thigh/drum cutter and static un-loader.

All pieces can be collected in a synchronized conveyor with pockets.

The Foodmate Food Service Cut-Up System is supplied with auto correcting magnetic cut-up shackles which significantly reduces the opportunity for shackles to be turned in the wrong direction when entering the cutting modules.

The unique turn point and side plate configuration makes the machine easy to clean and flexible for future line modifications. The stand-alone machine requires minimum installation time because all of the single point connections are integrated into the machine.

Includes the Following Machines:

• Tail Cutter
• Wing Stretcher
• Wing Cutter AFS
• Fat Puller/Pre-Cutter/Keelbone Cutter
• Lengthwise Halving Machine
• Halving Machine 2
• Thigh/Drumstick Cutter
• Flexible Unloader
• Control Box

Key Benefit:

• Allows for a maximum of 6,000 birds per hour.

https://www.youtube.com/watch?v=8EEYRmvlCKA

Foodmate IChickSort®UK developed a Poultry Grading for the 21st century.

Foodmate|ChickSort®UK InVision has been developed to take advantage of the latest camera technology and LED lighting. Utilizing multiple cameras, fronts and backs can be graded accurately based on user definable parameters which can be tuned to suit different flock profiles.

The data collected is added to the bird weight captured at an in-line or transfer weigh station and the birds are correctly distributed according to production requirements set on Foodmate|ChickSort®UK.

Employing multiple cameras and advanced software algorithms grades can be allocated in various levels of severity for the following conditions on fronts, backs or fronts and backs. The system can be set to recognize repeat downgrade conditions and trigger an alarm

if a number of birds are downgraded for the same reason within a set time. This could be invaluable if a machine setting downstream is causing repeat damage.

ChickSort®UK coupled with Foodmate|ChickSort®UK InVision can be configured to automatically produce a flock histogram after 100 birds.

The system retains images and this data can be recovered and investigated if quality issues have arisen at a later date. The flock can be “re-run” offline and the downgrade parameters checked. This feature can also be used for quality personnel training purposes.

Employing multiple cameras and advanced software algorithms grades can be located in various levels of severity for the following conditions on fronts, backs or fronts and backs.

• Broken wings
• Missing parts
• Skin flaws/Barking
• Bruises
• Feathers
• Single Leg Hang
• Hock burn
• Hock length
• Bile Stain