foodmateus.com

Foodmate brought a test machine to Fieldale, so their team could run tests with their product and assess if the machine was a good fit. After extensive testing, the Fieldale team found that the MAX delivered a consistent 3% increase in yield comparing to the previous equipment. We know a machine is not going to do as well as a fine-tuned cone line; everybody knows that, but the task was to find a balance between yield and the number of people in production you can get versus with a cone line. We have had an excellent working relationship with Foodmate, so we brought the MAX6000 test machine in, and after running a lot of testing, we found that between the previous equipment and the Foodmate Max6000, there was a consistent 3% increase in yield due to the quality of meat coming off the machine.

The goal for this plant was to replace hand-thigh deboning lines to achieve a higher production level while maintaining yields and reducing labor costs. Foodmate has replaced the plant’s hand thigh deboning lines with 3 OPTiX Thigh Deboners. Our team analyzed the plant’s needs and developed a solution that addressed the main goal: maintain or increase yield and decrease labor. To that end, our engineering team provided a plan to include three OPTiX Thigh Deboners, two OPTI Flow Cut-up systems, which included replacement of the chain, shackles, and leg processors of their existing line to send an anatomical cut whole leg to the OPTiX.

This project comprised a total rebuild, which went from a big bird deboning production to running products exclusively for a leading fast-food chain that focuses on a high-quality product. With the New Cut-up and Breast Deboner install, we are running at 100 birds a minute with fewer people than it took to run 35 birds per minute, so we can clearly see the labor reduction brought by a much higher product quality improvement. With the New Cut-up and Breast Deboner install, we are running at 100 birds a minute with fewer people than it took to run a 35 birds per minute, With the New Cut-up and Breast Deboner install, we are running at 100 birds a minute with fewer people than it took to run a 35 birds per minute, so we can clearly see the labor reduction brought by a much higher product quality improvement.

In order to increase profits in deboning whole legs, Springdale, AR based George’s Poultry knew they had to significantly reduce their staffing cost and increase pounds per man hour while not sacrificing yield and quality. In order to validate estimated yield numbers presented by Foodmate, and to verify machine could meet quality standards expected by their customers, George’s management team decided to run a test at the Foodmate facility in Georgia, where a brand new machine was available for testing. Although the total capacity needs called for 3 machines, George’s started the projects by purchasing one machine, to make sure that the equipment performed the same in real production. We look forward to phase 2 of this project which will further reduce labor costs with the installation of the automated J-cutting module into the cut- up lines.