The water jet portioner, a computer technology that utilizes thousands of pounds of water pressure to cleanly cut product in seconds, has yet to flood the red meat industry as a champion of new processing equipment. But that could soon change.
Only a handful of red meat companies-most notably Hormel Foods Corp. and IBP Inc.-have the water jet portioner in place. Currently, the water jet portioner, which calculates product size, shape and weight before cutting it, is heavily used in the poultry industry.
A spokesperson for Hormel would not comment on the performance of the water jet portioner in the company's operations. But more red meat companies may soon adapt the technology, according to sources.
The water jet portioner consists of video cameras that watch product on a conveyor belt. A computer generates a topographical map of each piece of meat, and the software determines the optimized cut for the highest yield.
"The biggest hesitation we have from the red meat industry is that [equipment personnel] do not completely understand the benefits [of the water jet portioner]," a supplier says. "But that is not a criticism. It's our responsibility to educate them."
What does the system offer?
What does the water jet portioner have to offer? Improved yield is arguably the most important feature that will attract processors. Improved yield will lead to financial gains, a supplier notes.
But attaining improved yield is not as easy as it sounds in the red meat industry, especially when a water jet portioner is sizing up inconsistent shapes, sizes and surfaces of primal cuts of meat.
The equipment is more compliant to the poultry industry because the cutting portions of meat are more consistent in size and shape.
"It's much easier to mechanize in the poultry industry," a supplier says.
The water jet portioner's vision system plays a critical role if the system is to function aptly in the red meat industry. The vision system has to correctly identify odd shapes and sizes.
Red meat processors have relied heavily on and have become comfortable with visual examination from human workers.
"[In the red meat industry] workers have to look at a product and make decisions on what to do with it," a supplier notes. "That process is difficult to automate. It is not anything a blind man can do."
As sophisticated as some machinery is today, it still cannot replace some human tasks, a source admits. But if the water jet portioner functions correctly, red meat processors can count on better yields and labor savings.
The water jet portioner is being used in the trimming of pork bellies. "We've locked in on the process, and we're near to making it a successful undertaking," a supplier notes.
Use of the water jet portioner will be focused in another area when the pork belly operation is deemed successful, the supplier says.
"The only way to move on to the next task is to be successful at the first task," the supplier adds.
Some contend that red meat processors have been hesitant to invest in the water jet portioner because of capital risk.
"But we are hearing of more money being made in the industry," a source notes, hinting that he expects more red meat processors to be open-minded about purchasing the system which costs $500,000 to $750,000, depending on the application.
Fine-tuning
Implementation of the water jet portioner involves more than just setting it up in a plant and flicking the "on" switch. Certain specifications have to be studied and met.
"And there is almost always programming after the installation," a supplier says. "There is a learning curve with this kind of equipment."
But a water jet portioner's hardware should not change over the years. Only software is altered to fit certain specifications, such as new computer boards.
The bottom line is the bottom line, a supplier claims. A company that adequately utilizes a water jet portioner can expect a payback and increased production with improved yields. The payback can result in as quick as seven months, the supplier notes.
"A water jet portioner has much more capacity equivalent to floor space for a hand line," the supplier says. "It is an efficient operation."