Ergonomic packaging line at Ameco

When abattoir Ameco decided to move from Amsterdam to a brand-new building in Apeldoorn, there was a lot that needed to be arranged. Its long-term partner Kortlever would play a prominent role in setting up the packaging line—there was no doubt about that. 

“Our collaboration began about ten years ago,” recalls Ameco’s director Jan van Westreenen. “At the time, we had a rather small space in Amsterdam. Kortlever came in with logistic solutions that created a great deal of order and peace of mind. Our process became more efficient and more ergonomic. It was a pleasure to work with them.” According to sales manager Gery Kortlever, Ameco’s primary contact at Kortlever, the click was mutual: “It is an incredibly dynamic business that is constantly in motion and always open to innovations.”

Collaborative thinking

In recent years, both parties have worked together closely on several projects. Therefore, it was a logical decision for Ameco to collaborate with Kortlever again in Apeldoorn. “We know from experience that they are a great, progressive partner that provides good service. They employ resourceful engineers who collaborate on solutions and the results are high quality. This is why our Amsterdam line is still in the same great condition that it was seven years ago.”

Ergonomic

Ameco wisely takes advantage of gravity throughout its slaughtering line in order to make work for its employees as easy as possible. That has also been implemented in the final stage of the process. Kortlever developed an entirely new sorting and packaging line, an area where ergonomics and comfort is essential for employees. The various meat parts are vacuum sealed along the vario-deboning lines. The items are then transported to the weighing and labelling stations. The labelling process is very simple: the employee clicks on the photo that corresponds with the part of the meat in front of them. Weighing is done automatically, after which the machine prints the proper label. “We thoroughly consider ergonomics during the design process,” says sales manager Eyad Zaatreh. “It is best when employees are only required to walk back and forth as little as possible.” Further along in the line, employees sort the vacuum-sealed meat parts into boxes and crates. A conveyor belt transports the packages and the employee sorts them out. To do this, they tilt the belt, which is a bit higher, towards the box or crate below. If the box or crate is full, then it is pushed towards the back. The box is pushed onto a different conveyor belt and is transported to the crate and box weighing station. Here, they each receive their own label. Crates and boxes are then automatically sorted before being loaded onto pallets. This minimises the amount of pushing and lifting required. “The line is ready for the future: it can easily and quickly be scaled up. If Ameco desires it, we can also automate the loading of empty crates,” says Eyad. 

About Kortlever
Over the past few years, this family business from Meerkerk has developed into a well-known producer of turn-key systems, processing machines and logistics solutions for industries such as meat processing, produce, snacks, and bread. Gery Kortlever: “We make it possible to work more efficiently and to replace “manual labour” with automated systems. Upon request, we will handle part of a line, as was the case with Ameco’s packaging line. However, we also create and install entire production lines. Thanks to the use of synthetic materials and ceramic-blasted stainless steel, all our equipment satisfies the strictest hygiene standards. 
From 20-23 March, Kortlever will be demonstrating its new and existing innovations at Anuga FoodTec in Cologne. The team will be located in hall 04.2 at stand A-031.
www.kortlever.nl

Planning and testing

Before the line is installed, it is extensively tested at the Kortlever factory. “We always do that,” says Gery. “It is more practical for everyone that we do the testing at our factory rather than on the shop floor. The client is very involved in this process. We offer solutions that frequently deviate from the standard and consider it important to know whether our solutions align with what the client expects of us. If necessary, we adjust the components.”
Jan is happy with his new line and he is not the only one. “My staff is visibly pleased,” he says. “They smile while they work, something which has become simpler and easier for them.” He has good things to say about how well the process went, too. “We met with Kortlever beforehand to discuss what we wanted. They have experience with other abattoirs and logistics solutions, which was quite useful. We created a plan together and barring a few small adjustments, it went exactly as expected. We will keep coming back, because Kortlever always does quality work. Recently, after the update to the sorting and packaging line, a line for ground beef was developed. We never stand still: there are always new plans on the horizon.”

www.ameco.eu