Show highlights new equipment, systems and services for the international meat industry
Industry executives who traveled to historic Frankfurt, Germany, in May to attend the ninth IFFA (International Trade Fair for the Meat Industry) trade show shared one major challenge: trying to cover every exhibit.
More than 900 suppliers from around the world showcased their wares at Messe Frankfurt. Even though shuttle busses and huge moving walkways helped visitors travel from building to building, traffic in the exhibit aisles was often times shoulder to shoulder. This made trying to thoroughly review all of the exhibits in six days a formidable task.
The mood was very positive during the show's entire run and was even reflected in this year's IFFA theme: "Meat Has A Future." Exhibits consisted primarily of slaughtering and processing systems and machinery; packaging materials and machinery; and meat products.
"IFFA is the best show of its kind anywhere," said a U.S. meat industry executive. "You get a chance to see everything that's new and innovative in the industry."
When asked which exhibits were the most interesting, he replied with a laugh: "How much time do you have?"
In the pages that follow, Meat Marketing & Technology reviews some of the newer, more innovative products and services that were on display.
Two-minute continuous
ham cooking unit
It takes only two minutes (instead of six hours) to cook a ham in the new APV RF cooking line, which offers higher efficiency, according to the company. Traditional cooking lasts three to six hours and may result in non-homogeneous, overdone product, which also involves a slow and expensive packing procedure.
In using the APV RF-cooker, APV claims the high frequency heating process provides a quick, uniform heating of ham and improves the taste, structure and water absorption ability of the product.
The feed pump is specially designed for a constant, pulse-free pumping of solid meat up to 13 pounds. The pump sucks the meat from a buffer reservoir into a hopper, which is kept under constant vacuum. Still in a vacuum, the meat is pressed forward into the cooking chamber, thus providing the maximum air extraction.
A sensitive metal detector with a valve ensures no metal particles are in the meat.
The RFC-50 cooking unit shapes and heats the meat homogeneously to the desired shape and temperature. The heating is an ionic dielectric process, and the cutting unit-type CMC 100 cuts the meat automatically to the desired length or according to weight. An integrated hot water rinsing sequence cleans the cutting knife before each cut.
The temperature transmitter ensures that the correct cooking temperature has been achieved. The temperature is recorded and data sent to the central unit to be used for quality control. The flow packer is specially developed for packing hot and moist products in flexible foils, which are 100 percent air tight.
The meat is sent directly from the cutting knife to the packing foil. Product is packed and sealed from the top. The packet will be fully welded at one end, and-to take account of the vacuum sealer-spot-welded at the other end.
The check weigher records the weight of the packed product and sends this data to the central unit to be used for quality control. The ink jet printer receives all of the production data from the central unit and prints this data on the packet.
The built-in feeder places four packets into position under the vacuum dome, which closes automatically. The packets are then subjected to vacuum. When the selected degree of vacuum has been obtained, the packet will be finally sealed, and any surplus foil is cut off and automatically sucked away. The dome is opened and the four packets are transported to cooling and cutting.
The entire process is controlled by the central unit, the APV Micromaster 2000, including collection of production data.
The RFC-50 can be connected to different production lines such as deep-draw machines for consumer size packets, roast lines for special products, smoking chambers, slicing equipment and cooling lines.
For more information, call APV Crepaco-Lake Mills at 414/648-8311.
Automatic cutting system
Attec Danmark A/S's Automatic Cutting System AG-2000 leads to better quality and higher yields, reports the company. Results show that the automatic system produces more accurate cuts, which means closer to the specified cutting positions than manual cutting.
Before the carcass is guided into the cutting system, the head and the tenderloin are cut off while hanging. In the first operation, the carcasses are automatically laid down on a laying-down conveyor and at the same time the hind feet are cut off automatically and collected. The laying down conveyor moves the carcass to the next station where the half is corrected to ensure that it is placed at a right angle on the belt. Simultaneously, the half is pulled across the belt by a fitting catching the pelvic bone in order to place the carcass correctly to the fixed hind-leg cutter.
During the movement across the belt, the distance from the pelvic bone to the caudal edge of the triceps brachia muscle is measured. This measurement is used to adjust the moveable fore-end cutter. The half-carcass than leaves the fixture and is cut into three parts by the other two rotary cutters. This system can easily be converted into a semi-automatic operation.
For more information, call the company in Denmark at +45 74 40 76 44.
Hot dog conveyor
The new Townsend Taco Conveyor allows processors to hang product (cocktails, viennas, foot longs, curved casing, quarter pounders and one up/one down) every time.
Set up is quick and easy, and it attaches to any RT series SuperMatic. It features an advanced design looper and rotating deflector.
Minimum adjustment is needed when switching product sizes, increased production is possible if hanging problems limit speed, and all stainless-steel frames will give processors years of trouble-free service. This has been a tested and proven operation in sausage plants. The conveyor nearly eliminates lead-end jams and product pile ups.
Built-in wheels make it easy to move for clean-up and relocation.
For more information, call 515/265-8181.
Automatic hog splitting
Durand International's Fully Automatic Hog Splitting Machine offers many features.
The hogs are split without manual intervening when passing on a conveyor; however, all operations can be done manually, and splitting is done while hogs are hanging on hooks or gambrels. Splitting is done by a cleaver without presenting any bone splinters or sawdust nor breaking of the spine. The split can be done through-or the split can be stopped automatically on the head.
The new Type MSP 6095 Automatic Hog Splitting Saw has output of 450 hogs an hour. Advantages include high capacity, hygiene, excellent yield, reliability, and split by circular saw.
Los Angeles-based Clougherty Packing Co. reported it installed this saw in its plant in July. Type 6092 is the new generation, and is made of stainless steel construction. Capacity is 450 hogs an hour. Type 6080/6085 contains a translation device for splitting while the conveyor is moving. Type 6083/86 is for splitting hogs while standing still. Capacity is 200 hogs an hour.
For more information, call (33) 75 85 92 22.
Automatic sausage production
handtmann's AL-System PH 210 features automatic sausage production from the vacuum filler directly onto the hanging unit. The linking performance, portioning range and portioning precision of this vacuum filler can be fully utilized. For the user, it means all types of sausages, from cocktail sausages to rings, can be flexibly produced with an increased level of automation.
The operation of this new system comprises portioning, linking, forming of sausage loops and transportation of the loops on the hanging unit. This rationalized sausage production requires a handtmann vacuum filler with monitor control, a holding device with the relevant deflecting device, the worktable with a control box, and a hanging unit.
For more information, call 708/808-1100.
Computer design for plants
Intercool Food Technology Ltd.'s Inter-media System is an easy-to-use computer program on CD-ROM, designed for engineering consultants and departments in slaughterhouses to assist them in designing slaughterhouses and meat processing plants in their own offices.
The program shows the different equipment from all major manufacturers. Presently, the program is made for hog slaughterhouses and further processing. Programs for beef, lamb and poultry will be available in the future.
The program takes the user through a plant step-by-step by clicking a mouse onto those items of interest on the menu, and by following instructions that appear on the screen.
The program is a combination of video, audio, graphics, animation, drawings and text. Some portions of the program contain a video focusing on certain aspects of the operation, which appears in a small box on the screen.
Some videos are accompanied by audio, and users may also click onto certain pieces of equipment or systems to get more information on these specific items, such as voltages, water consumption, size, and the way it operates. The program takes the user through the following areas: lairage, slaughter, cutting and deboning, processing, packing, chill, edible by-products, in-edible by-products, control systems, wastewater treatment, and general equipment. Windows PC and a DC-ROM drive are needed to operate this program.
For more information, call the company in Denmark at +45 33 12 31 58.
Vertical de-boning
The Desos' Vertical De-Boning System distributed by Intercool Food Technology Ltd., an engineering and contracting company in Denmark, is a process and system of equipment used for the vertical boning of quarters of cattle and other animals bred for slaughter.
The process allows for the boning of forequarters and hindquarters on a single combined production line.
The modular system's installation (single line, L-plan, U-plan) can be adapted to suit the layout and production requirements of a plant floor. The Desos' System procedure also allows the primary cutting and boning of veal and pork to be carried out on the same production line.
Product moves along the line from an overhead rail system. In de-boning a hind quarter of beef, a worker at station I loosens the aitchebone at the silver side and rolled rib by knife. Station II involves the tenderloin being cut loose, and the rib and the flat bone being cut by a circular power saw. Station III is where the knuckle bone and round bone are separated in the knee joint by a pair of pneumatic scissors while the quarter is elevated and the hook removed. (After this operation, the hook is fixed in the Achilles tendon.) At station IV, a pair of tongs grip the aitchebone while an arm fixes the position of the quarter from behind. Controlled by the operator, a pair of tongs pull while the backbones are cut free.
Next, final boning of the ribs and flat bones take place. This procedure has been adapted to meet European and Japanese requirements-particularly ergonomics, hygiene, yield and capacity. For more information, call the company in Denmark at +45 33 12 31 58.
New chub machine
Tipper Tie's SV 4600 Chub Machine is a new concept in the high-speed automatic manufacture of chub products using shirred fibrous, collagen and plastic casings.
The casing is voided of meat before the clips are applied to ensure clean tails and secure closers. A hanging loop and tape label for code dating can be automatically applied under the clip.
Two models are available, one for larger 2-inch to 5-inch diameter casings and a second very high-speed unit for three-quarter inch to 3-inch casings. Full electronic controls, with production programs and diagnostics, are standard. The machine operates with any industry standard filler, and uses reels of pre-formed Tipper Clips.
For more information, call 919/362-8811.
Continuous sterilization and
aseptic packaging unit
Metalquimia's Continuous HTST Sterilization and Aseptic Packaging Unit offers the most advanced technology in sterilization and repackaging in manufacturing cooked meat products, combining maximum efficiency with minimum space, the company states.
The cooking-pasteurization process plays a vital role in the manufacture of cooked meat products since it is responsible for the coagulation of muscular proteins, inactivation of enzymes, formation of characteristic flavor and aroma, stabilization of color and destruction of the vegetative microbial flora present in the meat mass (pasteurization).
The HTST system operates directly on the meat surface by means of a high temperature thermal shock (above 302 degrees F) and a short processing time (two to four seconds). The combination of said thermal processing with an automatic packaging in aseptic conditions guarantees the efficient elimination of the superficial microbial flora without altering the product's organoleptic and nutritional properties.
For more information, call (34-72) 214658.
Sausage grinder
The Vemag Sausage Grinder Type 980 for Robot HP Fillers is a one-step process: grinding, filling and portioning of fresh sausage and salami products.
It yields products smear-free and with perfect particle definition. With an attachment for the Robot HP, processors will achieve a product quality equal to one directly out of a cutter or grinder.
Features include compact grinder head with small dimensions. Plate diameter is 3.84 inches; knife set length is 2.8 inches; and distance between knife set and double screw is 3.4 inches. Patented grinding set for a throughput of eight tons an hour consisting of five pieces: precutting plate, medium hole plate, finishing hole plate, and two knives with up to 10 blades each cutting on both sides.
The grinding set is driven by a shaft connected to the special, closed double screw. The grinder housing is made from stainless steel and comes with an adapter to connect filling horns, clipping machines and the specially designed linker gear 828 to twist link various casings. Using spacer rings, the five-piece knife set can also be changed to a three-piece set by reducing by one plate and one knife.
For more information, call 617/821-1290.
Collagen casings from Germany
Naturin GmbH & Co.'s edible and smokeable, straight or curved casing is made from high-quality collagen for wiener, bratwurst and other dry or cooked sausages.
Naturin invented the first edible casing, reports the company. This casing is very economical to process, and enjoys greater popularity among discriminating sausage-makers throughout the world. Advantages include tender bite; good boiling and frying behavior; regular and natural smoking color; good flavor absorption during smoking; strong to fill; permeable to smoke and water vapor; economical to process because of machine-adapted, ready-to-fill shred delivery format. Uniform diameter means uniform sized sausages.
For more information, call Brechteen Co. at 810/949-2240.
The powerful cat
The continuously adjustable automatic feeding system makes the Treif Puma CE F a versatile helper in supermarket meat departments, catering businesses and commissaries.
The extra-wide chamber with an 8.8-inch by 9.6-inch cross-section holds chops, escalopes and steaks, as well as T-bone steaks and other products. The patented dynamic feed system provides a continuous supply of the product to the cut-off knife. The result is uniform cutting thickness and no bone smear at a speed of 400 cuts a minute.
Cutting thickness, first cut and tolerances can be easily programmed via diagnostic panel on the Puma CE and retrieved quickly via push-button-thus assuring cuts of constant weight. Various types of cut-off knives guarantee precision cutting: the long, serrated single knife is especially suited for bone-in product, and the double straight-edge knife slices with precision even at high cutting speed. The Puma CE comes in two models: trough lengths of 28 inches or 44 inches.
For more information, call 203/847-9699.
Continuous fat analyzer
Wolfking Danmark A/S's On-Line Continuous Fat Analyzer was developed in cooperation with the Danish Meat Institute. The CFA system, delivered as an integral part of the Wolfking mixer program, is operating on a principle where a pneumatic pump automatically selects a sample about every three seconds and processes it through the CFA for analysis. Each sample is analyzed several times, giving the result on each sample a high degree of accuracy. The measuring of each sample is performed by Near Infrared Spectrometry in combination with advanced computer processing of the data by using the concept of neural network. Apart from being the only available on-line continuous system, CFA is unusual because NIT is indifferent to variations in temperature, particle size, type of product or additive content, such as salt or proteins.
Examples of on-line applications for any type of pre-mix with fresh and/or frozen beef, pork, mutton, chicken or turkey include:
-- Hamburgers, patties, meat balls.
-- Sausages, bolognas, mortadellas.
-- Dry sausage, cooked salami, chorizo.
-- Minced meat, pizza toppings.
-- Nuggets.
Operators enter the recipe data and the batch weight into the computer program. The analyzing of samples by the CFA and the internal processing of measuring result is shown continuously on the readout of the control screen. The mixer is automatically stopped by the CFA when the continuous measurements obtained stay constant.
There is easy access to perfect standardization because the computer will tell the operator the amount of lean meat or fat to be added to the batch in order to reach the correct fat percentage. By using the CFA, the time for external meat analysis is avoided which increases the capacity of the mixer as well as offers savings on labor costs. The accuracy of plus or minus 0.5 percent of the CFA is better than most available lab systems.
For more information, call 614/863-3144.
Faster and better slicing
The Weber Computer Slicer CCS 9000 slices a great number of products faster and better, the company claims.
Exact slice thickness guarantees portions of correct weight when using calibrated products. Portions of correct weight when using non-calibrated products is a particular feature of its cutting and weighing line.
The circular knife, located on the discharge side, lays the slices precisely. The result is optically perfect stacks or layered arrangements.
The CCS 9000 is controlled by a high-capacity computer.
For more information, call the company at 0041-42-443136.