Smart and efficient processing system for chicken fillets

Processing chicken fillet; that's what Van Leeuwen Chicken Specialities is all about. As quickly and as flexibly as possible, while maintaining the highest quality. With this in mind, Jansen Techniek, in collaboration with Marelec Food Technologies, designed an advanced processing system for transporting, sorting and packing fillets.

Cees van Leeuwen, director/owner of Van Leeuwen Chicken Specialties, says that their history with Jansen Techniek goes back a long way. "We wanted to further automate our current way of working and eliminate human errors as much as possible. We have been working with their machines for years. It was self-evident for us to place this task with them. Founder of Jansen Techniek, Jannes Jansen, is happy with this trust: "Van Leeuwen has given us the opportunity to enter into a beautiful and challenging project with them. We have years of experience in automating production processes, but the application of Marelec's MATRIX production software was a first for us". Together with Van Leeuwen and Marelec, Jansen wanted to set an example for the industry: a system with maximum flexibility, perfect sorting and minimal giveaway on the end product. An increase in capacity with an equal number of employees was also an important goal.

Photo: Jannes Jansen (l) en Cees van Leeuwen

The processing process

The newly realised processing process at Van Leeuwen starts with the insertion and weighing of the incoming meat. Each pallet is marked with a barcode that enables the products to be traced throughout the entire process. The fillets are then harvested on the filleting lines and transported to one of the five Marelec sorting lines. These sorting systems each have 30 batch outlets and can weigh and sort up to 800 fillets per minute. The previously set batches are sorted and dropped onto the take-away conveyor with batching hoppers. "The batches are then placed in trays," says Jannes. "Each tray is provided with a unique QR code and linked to a specific batch. In doing so, each batch is placed in the right scale and the traceability of the products is guaranteed. On the basis of the QR code, a JCS checkweigher determines whether the target weight has been achieved. Incorrect weights are removed, updated and entered back into the product flow".

Packing and shipping

After weighing, all approved products are collected on the central conveyor belt. Three packing machines seal the trays, after which they pass through a Fortress metal detector that checks for metal contamination. The approved trays receive a top label. Every last tray of a packaged box receives a box label, after which the system sends the trays to one of 56 addresses. This is where they are packed into boxes and palletised. Ready for shipment.

MATRIX, the connecting factor

Indispensable in the entire process is Marelec's MATRIX order processing system. According to Jannes, every producer knows how important and interesting it can be to follow the production process in real time: "A customer wants to be able to see which orders are ready and what the yield of a specific batch of raw materials is at a specific moment in time. This is where MATRIX software from Marelec excels. Marelec's share in the Van Leeuwen project is large because there is so much software available. Everything has to come together at the right time. When you consider that up to 800 fillets per minute are passing by, a lot happens during the process".

MATRIX is a complete IT platform to optimize processing performance and profits. The system is constructed modularly with modules for monitoring trim lines, graders, portioning machines and packaging and shipping systems. MATRIX connects everything; from the supply up to and including the storage and shipping of the finished product. This total production monitoring provides the manufacturer with accurate control and information for maximum efficiency.

Five steps forward

"When I visit Van Leeuwen, I see that people are happy to work with these machines. Which makes you proud" concludes a satisfied Jannes Jansen about the project, "All the more so because they can make 15% more turnover in the same production time! For us, a deal isn't just about delivering something and then quickly moving on. No, we go for long-term relationships. A project is only finished when the customer is really satisfied". At Van Leeuwen Kipspecialiteiten that appears to be in order: "I think we have taken five steps forward with this line, ready for the future. We can sort our portions more accurately and serve our customers even more precisely," says an enthusiastic Cees van Leeuwen: "Our experience with the machines at the moment is really top-notch. It is absolutely something unique. The boys from Jansen are great guys."

www.vanleeuwenkip.nl
www.jansentechniek.nl

Photos: © Van Leeuwen Kipspecialiteiten