2009 – Volume 2
Food processing
Time to make
the next move
5 Consistent breading to perfection 6 Rationalisation with pace boning line 8 Leadership
takes discipline... 9 Top-of-the-line in salmon 11 Winning line for fish production
CO N T E N T S
2
New CEO of Marel and Stork Food
Systems
Theo Hoen has been appointed new CEO of Marel
and Stork Food Systems
3
Four way fish line at Lusamerica
Packing and labelling four different types of fish
simultaneously with AEW Delford equipment
4
Marine Harvest invests in spiral freezers
Dutch plant impressed with two Dantech spiral
freezers recently installed for breaded fish products
New energy saving freezer
Marel Food Systems have added a new energy
saving freezer, to its existing range
5
Breading to perfection
The new RotoCrumb from Stork ensures constant
even amount of crumbs for breaded products
6
Rationalisation with pace boning line
Higher yield and fewer operators as a result of a new
pace boning line at Danish Crown
PolyLine at Konsum Varmland
Efficient and cost saving automatic slicing line
7
New PortionCutter I-Cut 10
Automatic fixed weight portioning at high speed
and low cost
8
Cost leadership takes discipline
Interchicken relies on automation and improved
logistics from Marel Food Systems
9
Top-of-the-line in salmon
Gastro Fish invests in the most advanced and
automated salmon processing line available
10
Introducing a new M-ployee
The new flexible and hygienic check weigher,
M-Check RF8, is applicable for both wet and dry
areas
11
RevoFormer from Stork Food Systems
The low-pressure forming machine ensures products of a consistent size without losing texture or
structure
12
Process Consultancy
Process Consultants are highly valued at customer
sites where they help implement new and efficient
processing techniques
CEO of Marel and Stork Food Systems, Theo Hoen
New CEO of Marel and Stork
Food Systems
The Board of Directors of Marel Food Systems has made an
agreement with Theo Hoen to lead the united companies
of Marel and Stork Food Systems as CEO.
Theo Hoen has an excellent track record as CEO of Stork Food Systems
from 2001 to date and has close to 25 years of experience in the
industry­, having previously served as head of R&D and production.
Under his leadership, Stork Food Systems has become the global
market leader in serving the poultry processing industry and has at the
same time delivered strong operational results.
“In May last year, a dream came true when the two great companies of
Marel and Stork Food Systems joined forces. The two companies had
been industrial partners for over a decade and the merger was finally
achieved. After a period of successful acquisitions, we will now focus
on increasing synergies and leveraging our strengths. Our future is
bright and our aim is to realize our full potential.”
Theo Hoen, CEO of Marel Food Systems.
Four way fish line
“This system is the most flexible, userfriendly product available on the market
today. It enables us to efficiently and
accurately meet any customer labelling
demands, regardless of how cumbersome or complex they may be.”
Tony Silva, Lusamerica Plant Manager
Simultaneous weigh price labelling of up to four
fish species at Lusamerica.
California based Lusamerica Fish processes a wide range of
very high quality fresh and frozen fish, seafood and seafood
products, which it supplies to the world through an extensive distribution network.
Vital technology
Tight delivery schedules and the use of the most advanced
refrigeration and processing technology currently available
lies behind this extensive product range. An AEW Delford
converging and weigh price labelling line provides simultaneous processing of up to four different types of fish in a
range of different tray sizes.
At the heart of the system is a WPL8060 Weigh Price
Labeller­linked to a product converger with four dedicated lanes – one each for cod, salmon, Dover sole and catfish.
The converger­releases the individual trays on a first come,
first served basis and, because the 8060 is programmed
to identify­which comformat is being run on each lane, it
can identify what fish product is arriving at the weigh cell.
Throughputs range from 48 to 80 trays/minute according to
the tray size and weight.
As trays cross the weigh cell, the WPL8060 prints the appropriate label for that particular product with all fixed and variable information. Labels can be placed in a different place on
each tray, determined from the leading or trailing edge and
rotated if necessary.
A four lane packing station is installed at the end of the line.
The Weigh Price Labeller communicates directly with the
Totaliser/Printer Unit, which controls the packing station.
The Lusamerica packing station can have different batch
counts for each section, with the facility to set
4, 6 or 8 counts. Once the programmed
count is achieved, a light indicates
that the count is complete for that
particular channel. The operator
then simply presses a button
to print out three outer box
labels: two placed inside for
traceability and one applied
to the outer box as COOL
(Country of Origin Labeling).
For more information about weigh price labellers
see www.marel.com
Safeguarding your equipment’s potential
Extended warranty allows a customer to enjoy the benefits of a standard
warranty with additional advantages­over a longer period of time, following new equipment purchase. As well as extending the standard warranty­
terms (including time on site and replacement non wearing or consumable
parts), an on site inspection is included in each year of cover, to optimise
equipment performance, protect the condition of the equipment, and
provide expert advice on equipment operation best practize.
For further information see www. marel.com/service
3
Two spiral freezers
for Marine Harvest
At Marine Harvest Sterk B.V. in the Netherlands, 200 employees work on
processing all types of ready to eat frozen (coated) retail fish products.
The company recently placed an order with Marel Food Systems for 2 spiral
freezers­of the Dantech Arctic Flow type for ultra quick delivery and installation.
Marine Harvest is the first customer in the Benelux region to purchase a Spiral IQF
from Marel Food Systems.
4
To meet Marine Harvest’s requirements for an ultra short delivery schedule, the
new spiral freezers were supplied with stainless steel platforms instead of the
more usual concrete plinths. This alone reduced the installation time by more than
two working weeks.
The Spiral IQF freezers are each equipped with more than 300 metres of stainless
steel belt with a width of 680mm. Depending on product type, each freezer has an
hourly processing rate of more than 1000kg of products with core temperatures
down to -18 °C.
It turned out to be really easy for Marine Harvest to decide on a supplier for its
new spiral freezer equipment. The special Dantech spiral design enables Marine
Harvest to considerably reduce operating costs, and Marel Food Systems was
quite simply the only company capable of dealing with the space constraints and
the short delivery time.
Energy saving freezer range
The Freezing & Temperature Division of Marel Food Systems has
launched a new range of energy saving freezers, known as the
Energia Mk8 Superflow and Arcticflow series.
The Energia Mk8 freezer is the latest addition to the energy saving freezers from
Marel Food Systems. This freezer is available in single and twin-belt versions.
The Energia Mk8 design has the important advantage of being easy to adapt to
high-speed vertical air flows – the Superflow® version – and conventional highspeed horizontal air flows – the Arcticflow® version. This provides users with
maximum flexibility to determining ways to minimize freezing costs
Henrik Ziegler, Managing Director of Marel
Food Systems Freezing & Temperature
Division,­says, “At a time when production­
costs are high on the agenda, it is really­
important for the customers to have the latest
technology with the lowest possible energy­
consumption. Our new range of freezers­
provides the best solution in the market
today. With this new technology, we have
taken a major step into the future of freezing.”
Consistent breading
to perfection
Consumers are buying more and more ready to eat products. The share of these that involve added value –
such as products with a crispy crust – is also getting steadily bigger. To make sure the consumer buys your
specific breaded product, it is important that it retains an attractive appearance throughout the purchasing
process, during preparation and while it is being eaten.
friction while in the machine. This in turn helps keep crumb
structure in the best possible condition.
RotoCrumb also has the advantage of releasing the breadcrumbs evenly across the entire belt width of the bunker, via
a rotating drum. This prevents the crumbs from separating.
You can also undertake ‘mixed crumb’ processing, as well as
using especially delicate types of breadcrumb, such as Japanese crumb.
A RotoCrumb solution results in savings on raw materials as
well as consistent breadcrumb quality. It can even enable
you to add new products to your range.
Perfection with minimum crumb
The revolutionary transport mechanism featured in the
RotoCrumb crumbing machine does away with the use of
the screws, as found in traditional equipment. RotoCrumb
makes sure your products look perfect after breading,
making separating and grinding a thing of the past.
Because of the new dosing system, there are fewer crumbs
in circulation. This means the breadcrumbs encounter less
The Superflow Energia Mk8 Freezer is specially designed
for a great variety of flat and fragile products, such as
burgers­, fish fillets, nuggets, poultry fillets, mussels,
shrimps, diced meat, vegetables, fruit etc.
Special features of the Superflow®Energia Mk8 Freezer:
• Lowest energy consumption on the market
• Very small footprint
• Complies with the strictest hygienic demands from all
well known institutions
• Easy to connect to CIP system, as standard
• Very long running hours in between defrosting requirements
Excellent attachment
The new design of the RotoCrumb makes it easy to control
the make up of the breadcrumbs, so that your products
receive a consistent covering on the top and bottom.
Easy manipulation
The smart RotoCrumb design also makes it very easy to both
operate and clean. You no longer have to remove parts for
proper cleaning. The ingenious system can be slid apart so
that all hard-to-reach spots are easy to clean.
5
“The new installation has also ensured
better hygiene in the production area,
because it is easier to clean as a result
of the special welding technique that
Carnitech uses.”
Carsten Ole Hansen, Production Manager­
Rationalisation with pace
boning line
In 2008, Danish Crown in Ringsted, Denmark,
invested in a Carnitech pace boning line for
deboning and trimming pork bellies. Previously,
Danish Crown had been running its production
with deboning on tables followed by trimming
on belt conveyors.
6
“After installing the pace boning line, we need fewer opera­
tors­and we get a higher yield,” says Production Manager­
Carsten Ole Hansen. “The finished products are more
uniform, and we have increased both quality and efficiency­
considerably.”
“Another advantage of the pace boning line is that we can
easily change work stations, meaning that the operators
switch positions during the day in order to help prevent any
industrial injuries that stem from monotonous, repetitive­
work. And each station can easily be adjusted to the
individual­operator, with the height-adjustable working platforms ensuring that the work station is always ergonomically­
correct,” says Carsten Ole Hansen.
Danish Crown and Carnitech have cooperated on many
projects before, which made the choice easy. “The collaboration went well, both during the sales process and
installation.­­The Carnitech people were very professional,
and the line was up and running on time. Eeverything ran
immediately after installation,­without the need for further
adjustment,” says a satisfied Production Manager from
Danish Crown in Ringsted.
Increased throughput with lower costs
Just about every processor in the world is seeking to achieve increased throughput with lower costs
and Konsum Varmland is no exception. This highly successful Swedish cooperative produce a wide
range of baked goods, ready meals, and cooked, cured and fresh meat.
For some time now, there has been a trend away
from in-store retail delicatessens towards more efficient and cost-effective centralised packing using
trays produced on a thermoformer.
In 2006, Konsum Varmland’s Delicatessen Manager,
Kenny Thor, responded to the trend by deciding to
Konsum Varmland’s Delicatessen
Manager, Kenny Thor
source a new slicing line that would enable his company to
meet the increasing demand for this type of packaging.
Kenny drew up a detailed and demanding set of specifications. Speed and throughput, combined with slice quality­
and presentation, were, of course, essential if the pressures­
of growing daily demand were to be met. So, too, was the
New PortionCutter I-Cut 10
Automatic portioning made easy
The new PortionCutter from Marel Food
Systems, I-Cut 10, is a compact single-lane
PortionCutter designed for optimising fixedweight production.
With the new I-Cut 10 PortionCutter, Marel Food Systems
covers portioning at its basics. The I-Cut 10 cuts accurately to
fixed weight and/or length at a high speed, thus increasing
profitability by improving yield and reducing giveaway. The
small footprint of the PortionCutter makes it easy to fit it into
most production facilities – no matter what the size. Operating the I-Cut 10 is very easy using the M3000 display, which
is characterized by its simplicity.
High speed, low cost
Based on Marel Food Systems’ vast experience in fixed weight
portion cutters, the I-Cut 10 offers both a robust construction and technology resulting in low maintenance costs. This
ensures a competitive price, while keeping the same accuracy
and high speed features of Marel Food Systems’ other portioning equipment. A rapid payback is virtually guaranteed because
of savings on labour.
Flexible and hygienic construction
Together with the well-known technology of Marel Food
Systems’ portion cutters, the I-Cut 10 features an open knife
construction as well as excellent hygienic opportunities. The
two-door construction offers easy access for maintenance
and cleaning, thereby reducing the risk of bacterial intrusion.
Key features of the I-Cut 10
High-speed cutting that results in greater productivity
• Great accuracy, resulting in minimal giveaway
• Maximum profit because of fast payback
• High level of hygiene with easy cleaning access
• Reduced operating costs via the functional, simple design
of this low-maintenance portion cutter.
“Not only is the line very fast, it saves 4 opera­tors­and reduces product handling, which in turn greatly improves hygiene and presentation. The IPL Robot’s great ability to pack a variety of formats reinforces my view that robots are definitely­the future for our industry.”
Kenny Thor, Manager of Konsum Varmland’s Delicatessen
ability to handle a range of products in a variety of formats with precision and accuracy right
through to packing and despatch.
Kenny paid a visit to the Scanpack exhibition in Sweden and found just what he needed: an
AEW Delford PolyLine comprising a PolySlicer 3000, Intelligent Portion Loading (IPL) Robot, a
pack converger, a weigh price labeller and a packing station for packing and labelling crates.
The AEW Delford Intelligent Portion Loading Robot
gently places sliced meat in trays
7
Leadership takes discipline…
8
Poultry processor Interchicken has grown by leaps and bounds since its establishment in 2003, firmly positioning itself as one of the top three producers in the Netherlands. “Our goal is to be the cost leader in chicken fillets and to achieve that we have to be able to produce the fillets in a cheaper way,” says Johan Nap,
Interchicken’s­Operational Manager.
“We have had tremendous growth until now and our focus
has been on delivering whatever the customer wants. Now,
however, we are looking for a bit more standardisation and
predictability in our production,” Nap explains. Automation and improved logistics are the key in order for that to
happen.
Optimised fixed weight batching
Interchicken has made a big investment in increasing its
production capacity in the past year. The company now has
six Stork deboning lines from Marel Food Systems, up from
three at the beginning of the year. The company sells a lot of
fixed-weight products and recently decided to add the Marel
Optibatcher to its arsenal.
The Optibatcher is designed to create fixed weight or netweight packs with the lowest possible over pack – as little
as 1%. The Optibatcher batches 180 pieces per minute.
A dynamic in-weighing unit weighs each individual fillet
before it is sent to one of 32 collecting bins. The bins contain
precision scales that constantly monitor the batch weight
and send confirmations or corrections to the main computer. The fixed weight batches – usually 500 or 1,000 grams
– are then dropped onto a product conveyor, which is
synchronized­with a parallel tray conveyor.
“But now that we are focusing on optimising and increasing efficiency, we are looking
at more indicators. Not only ‘how much’ and
‘how fast’, but also yield and giveaway. And
it needs to be done if we want to achieve
cost leadership.”
Johan Nap, Interchicken’s­Operational Manager
Spotlight on yield and giveaway
“In the beginning, we just wanted to produce enough to
fulfill our customers’ needs,” says Nap. “But now that we are
focusing on optimising and increasing efficiency, we are
looking at more indicators. Not only ‘how much’ and ‘how
fast’, but also yield and giveaway. And it needs to be done if
we want to achieve cost leadership.”
The next step is, therefore, further integration of Innova –
Marel Food Systems’ new intelligent production management software – with Interchicken’s Enterprise Resource
Planning­(ERP) system. “Where are we losing value? On what
line? What machine? What supplier? We need a smart system
like Innova to help us with that,” Nap concludes.
Top-of-the-line in salmon
Johan Van den Steen, owner of Gastro Fish.
If you want to see the most advanced salmon processing line in Europe, if not the world, head over to
Zeebrugge, Belgium. That’s where you’ll find the rapidly expanding producer Gastro Fish and its brand new
4,000 sq. metre production facility.
9
A seamless flow, from A to Z
The new state-of-the-art processing line was installed
in September 2008. It spans the entire production process, from reception of raw material all the way through to
finished and packed product. The sequence kicks off with
the unloading of boxes of farmed Atlantic salmon and from
there the fish proceeds through desliming, deheading, filleting, trimming, pinboning, skinning, washing, packing, icing
and palletizing. All in one smooth, seamless and highly automated flow that culminates in a customized packing system,
developed jointly by Marel Food Systems and Gastro Fish.
The fillets are automatically packed into plastic boxes and
stacked on pallets.
Five fold increase in productivity
Gastro Fish’s investment is paying off handsomely. With its
sophisticated new line, the company has attracted many
new customers and sales have gone up substantially. So has
productivity. “The main benefit for us is that with the same
number of employees we have been able to multiply the
number of fillets we produce by five,” says Van den Steen.
Processing was previously done manually.
What’s more, in December 2008, Gastro Fish had exceeded
the expectations set at the beginning of the year by some
30%. “We were aiming for 25 tons of fillets per week by the
end of the year and we are now at 35 tons. We’ve been able
to do this because demand has been good but also because
the finished product is ‘correct’, meaning that the quality is
high and in accordance with the customer’s demands.”
Automation and reduced manual handling of the raw material mean that processing time has been shortened, reducing
the risk of bacterial contamination. The end result is a higher
quality and more uniform product, with increased shelf life.
Flexibility provides competitive advantage
The line has provided Gastro Fish with much more flexibility
in responding to customer demands. “The goal with the new
line was to increase productivity per operator while simultaneously reducing production time to a few days per week,
which we have achieved. This means that with same number
of operators we can now quickly increase the capacity when
new customers come knocking,” Van den Steen explains.
“My goal from the very beginning, when I began discussing this project with Marel Food
Systems about two years ago, was to have the most advanced and automated processing
line available.”
Johan Van den Steen, owner of Gastro Fish
Meet your new M-ployee
construction ensures high levels of hygiene, because this
checkweigher can be totally stripped down for cleaning. This
helps reduce any risk of bacterial intrusion.
Marel Food Systems introduces the new
M-Check RF8 checkweigher, designed to ensure
100 per cent weight control. The easy to clean
design also makes sure hygiene is at an all time
high. The M-Check RF8 can be used for sealed
as well as non-sealed packages, which ensures
effective integration into both wet and dry areas of the processing plant.
1 0
The M-Check RF8 is an all purpose checkweigher – built to
last. The simple yet very sturdy construction features a quick
release for the belt. The belt can also be adjusted without
any tools.
The M-Check RF8 features several configuration options,
including multiple reject units and lockable bins. As an
additional­feature, the checkweigher is available with or
without metal detection. The M-Check RF8 is, of course, fully
height-adjustable.
Hygienic benefits
The M-Check RF8 features excellent hygiene with easy
to clean surfaces and sealed bearing houses. The open
Strong software package
With the M-Check RF8 software, this checkweigher is capable­
of handling several different weighing jobs at the same time,
with a logical interface that gives a full overview.
The M-Check RF8 is designed for close integration with
Innova­, the Marel process software technology. This paves
the way for complete monitoring of the production process­
and enables users to carry out online production control.
In the case of problems with the power supply, a built-in
back-up power battery makes sure all software is shut down
correctly, making sure all data is saved correctly.
Key features of the M-Check RF8
• Specially equipped to deal with the
whole range of wet and dry food products
• Open construction permits easy access
to ensure a high hygienic standard
• Complete monitoring and control
of key performance indicators
such as efficiency and
traceability, via Innova
software technology
• Maintenance costs at an
all-time low due to a minimum of wear and tear, as well
as overload protection
• Quick-release belt
• Easy to integrate into large
processing systems
Low pressure forming of
meat products
Stork Food Systems’ response to the demand for further processed meat products is to provide systems
that meet the most stringent requirements set within the food processing industry.
Stork Food Systems supplies machines
for all the functions in the line: forming­,
coating, marinating and heat treatment. The absolute showpiece within
the Stork product range is the RevoPortioner low pressure forming machine.
Focus on quality
RevoPortioner combines high capacity
with high product quality and low cost
of ownership. The forming technology
offers an alternative to the traditional
method of forming that has been used
up to now. With the high pressure forming machines currently in use, formed
products display non conformities in
relation to the intended shape immediately after release and/or heat treatment. With the RevoPortioner, products
Winning line for fish
production
IPL Robot. Automatically loads fresh fish products into trays
or a thermoformer. Multi head versions are also available for
higher output.
Portionline fish is an integrated production
line specifically designed to provide automatic­
slicing and portioning of fish from start to
finish.­The complete system comprises a
number of proven machines from Marel Food
systems that are fast, efficient and accurate in
producing fixed or catch weight packs.
Intelligent production control from Marel’s revolutionary and
well proven Innova modular software provides full control
over the complete chain in the production cycle from reception of raw material to dispatch of finished product. All key
performance indicators (KPIs) are provided at each stage as
well as traceability from door to door.
Tray Sealer or thermoformer
G2200 Checkweigher/Metal Detector. Combined checkweigher and metal detector with high throughput.
Pack Turner. Provides motorised 90 degree pack turning for
correct presentation to the labeller.
WPL 8100 Weigh Price Labeller. Versatile, high speed Weigh
Price Labeller.
Stacker/Indexer. Collates and stacks a pre-selected number
of packs to facilitate case/crate packing.
PortionLine fish is just one of a range of dedicated slicing and packing lines from Marel Food Systems that can be
configured to precisely meet the needs of processors in the
meat, fish and poultry industries.
All this results in maximised yields and output, increased
throughput and efficiency, reduced labour costs and optimised product quality together with ease of operation and
easy hygiene.
A typical portionline fish system would include:
I-Cut 36. High speed, high precision portion cutter with
45 degree cutting angle capability.
Using low pressure for converting red meat dough into
products of consistent size.
RevoPortioner retains the white meat muscle
structure.
retain their typical shape and weight
and, consequently, there is very little
non conformity. The use of low pressure will ensure that red meat or white
meat, either mixed as dough or with
fully structured muscle, is converted into
products of a consistent portion size
without losing its texture and structure.
Product release
Up to now, water has been used to
assist the release of products from
the mould. The RevoPortioner uses air
instead. This offers benefits in terms of
bacteriological quality, which is particu­
larly important in the case of fresh
products. The use of air also benefits
product quality in terms of pro­cesses
further down the line, such as battering and packing. It also reduces­the
amount of dirt and soiling in and
around the machine.
1 1
“During Michael Pedersen’s visits, the
operators have been introduced to
new cutting techniques, which have
improved our yield remarkably.”
General Manager, Wayne Aspeling
Process Consultant, Michael Pedersen from Marel Food Systems is
training an operator at Enterprise Foods.
Marel Food Systems Process
Consultancy
Enterprise Foods, the largest pork producer in South
Africa­, is one of the many processing companies that
have benefited from the expertise of Marel Food Systems’
Process Consultants.
Process Consultancy is a specialist service available from Marel
Food Systems, either when buying and installing a new production
system, or to help optimise an already existing system. Enterprise
Foods took advantage of this service after installing a new deboning system from Marel Food Systems.
Consultancy challenges
To go from a simple cut-up and deboning process in an old fashioned deboning hall such as the one Enterprise came from and to
a complete new world with all new equipment and changes in the
Exhibitions 2009
production planning, is a huge step. Wayne Aspeling, General­
Manager at Enterprise Foods explains, “This type of system is the
first of its kind in South Africa, so it took a while for us to get to
learn how to best use its capabilities. Michael has been a decisive
factor in this process.”
Optimise the process, increase the yield
However, the core competence of the Process Consultants is to
optimize production processes and increase the yield. One of
the ways to achieve this is by optimising the standard cutting
patterns. Cutting meat the correct way reduces giveaway, and the
portions are now cut so that they give maximum possible profit.­
“Learning how to optimise the deboning process has been an
added benefit, but definitely one of the most important lessons
we have learnt from Michael,” Wayne concludes.
Dates
Country City
10-12.06.2009
16.18.06.2009
22-24.07.2009
18-21.08.2009
02-04.09.2009
16-19.09.2009
USA Poland Japan Norway Russia
Spain
Soldotna, Alaska
Gdánsk
Tokyo
Trondheim
Vladivostok
Vigo
26-28.05.2009
21-24.05.2009
13-17.09.2009
25-27.08.2009
Russia Italy Poland Brazil Moscow
Verona
Poznan
São Paulo
11-15.05.2009
17-20.06.2009
08-11.09 2009
28-30.09.2009
Spain Thailand Ukraine Holland Barcelona
Bangkok
Kiev
Utrecht
FISH
Global Food Alaska
Polfish 2009
Seafood Show Tokyo
Aqua Nor
Russia Seafood Show
World Fishing
VIV Russia
Eurocarne
Polagra-tech
Tecnocarne
GENERAL FOOD & PACKING
Technoalimentaria
Propak Asia
Inprodmash
National Foodweek
MEMBER OF MAREL FOOD SYSTEMS
www.marel.com
Subject to change without notice / 95006.02.09.int. Advantage
MEAT & POULTRY