Perfect Combination
by Larry Aylward, managing editor
The ultimate high-speed linking machine does not come equipped with more gadgets than James Bond's elaborate wristwatch.
The contraptions on the best high-speed linking machines are not complicated and are easily understood.
"The machines today have become simpler," a supplier notes. "[A complicated machine] is not the best thing for the meat industry."
The modern high-speed linking machine has less mechanical parts and is an engineer's dream. It has no linkage, looper horn or casing clamps. Processors can say good-bye to sprockets and chains.
Linking machines are less complicated internally, as well. Electronic control motors are being used to vary speeds accurately, an expert points out.
Less mechanical parts means quick changeover, a feature that is crucial to processors. And changeover would not involve tools or require specially trained mechanics.
With today's technology, sprockets and chains can be eliminated, thereby saving sometimes 15 to 20 minutes a changeover, the supplier says. The linker is also more reliable, the expert adds.
On older machines, an operator needed a pair of channel locks and an adjustable wrench to adjust a casing hopper from a 28-millimeter to 16-millimeter casing. On today's machines, the operator can toss the tools in the trash.
"One of the biggest gripes in a plant has been maintenance vs. operation," the supplier points out. "Maintenance is maintenance, and operations is operations. Operators should not have tools."
Basically, an operator with a tool may do more damage than good. Then the maintenance person may have to fix that damage-and the original problem.
Some applications on older high-speed linkers call specifically for changeovers involving maintenance personnel.
"It requires another human resource," the supplier adds. "It's not exactly cost-effective."
Weighty issue
Weight control is the most critical issue in frankfurter processing at Massillon, Ohio-based Freshmark Inc., says Jochem Pahler, a foreman in the plant that manufactures Sugardale products, including frankfurters.
"We pack 12-ounce and 1-pound products. We don't want to give the house away, but we don't want to be short either," Pahler says.
There are six high-speed linkers operating on Freshmark's premises. "We have an employee that runs from machine to machine to do weight checks to make sure the machines are [operating] in the parameters we want for our different-sized products," Pahler notes.
The supplier says modern high-speed linkers are available to keep weight control within one-quarter percent of a target.
"Some processors are giving away two percent," he notes.
Some modern high-speed linkers are equipped with improved metering pumps that have less gear wear in the housings, improving weight control.
Any processor who hits the streets shopping for a new high-speed linking machine should be thinking in terms of weight control.
"Weight control is the easiest thing to show payback," an expert says.
The main issues of weight control are simple: It is easier to control the weight of large diameter product, such as jumbo frankfurters. If it's a cocktail frank, weight control is more difficult.
"The larger high-speed linkers tend to specialize in large diameter products because it's easier to have weight control of larger products," the expert says. "The bigger the product, the easier it is to give it a low percentage of weight error."
Important weight control adjustments apply to the metering out and measuring of meat, and accurate pulling of the casing. Together, these functions determine the exact weight of each linked frankfurter.
"The smaller the product the more critical that becomes," the expert says.
What if a processor decides to stick with an old standby? What are the keys to proper linker operation then?
Burlington, Vt.-based McKenzie Packing Co. has a 10-year old high-speed linker in operation for skinless frankfurters.
"Because it's older, the machine is a bit temperamental," says Mark Dubie, McKenzie's plant manager.
It's not difficult to operate, but there is an art to running the machine, Dubie notes. A skillful operator is as important to a high-speed linking machine as the electric current that makes it hum.
"An efficient operator can make all the difference in how much volume a machine puts out," Dubie says.
McKenzie also manufactures natural casing hot dogs. Dubie wishes that high-speed linkers were designed to handle natural casings.
His wish may be granted. The supplier says he envisions a fully automated, high-speed linking machine for natural casings will be out on the market in the next year.
"The problem with natural casings is the sensitivity of the product," the supplier says.
To get around the sensitivity, the process will change from a linking head application to a stop-start application, the supplier notes.
Every 3,000 miles
There's a one-word reason that answers why McKenzie Packing has been able to get good mileage out of its high-speed linker: maintenance.
"We always rip it down once a year and rebuild it before the summer frankfurter season hits," Dubie says. Air pistons, solenoid valves and micro switches are maintained or replaced, he adds.
"It's just like a car," Dubie says. "When the gas mileage goes down, it needs a tune-up. It's the same with a high-speed linking machine.
"Watching the yield and weight control will tell you when a part starts to wear out," he adds