Bone line concept

The Pace Bone Line joins the Marel Flowline concept with each worker monitored for yield, throughput and quality, and the Carnitech Pace Line where the group work concept is utilised without requiring a skilled butcher.

The concept involves a series of group workstations, each of which may include several operators. Group workstations have one infeed buffer for incoming primal, a monitor for each operator that graphically displays cutting patterns, and outfeed buffers for finished products.

After automatic weighing, the primal is sent to a designated workgroup. Each operator performs his task according to the cutting pattern displayed. As the primal moves from one operator to the next, individual products from each operator are placed in one of the outfeed buffers.

A workgroup of four working on a leg of pork with cycle time 120 s, for example, will balance out to 30 s per operator. This cutting-pattern cycle might require operator number two to remove the topside, which is then released from buffer onto the main product conveyor. With the line it is possible to keep track of all products coming from individual workers, as well as workgroup units, by measuring yield, throughput and quality.

Each cut and trim is released onto a product conveyor that passes over a dynamic scale where the precise weight is registered. From there, the product can be selected for a QC check, or go directly to its designated packing gate. In the meantime, the workgroup is already processing another primal.

Marel's MPS system software monitors and controls the entire operation. The system enables managers to keep track of overall performance in real time, thereby maximising yield, throughput and quality.

MPS identifies weaknesses in performance, which can then be immediately addressed. The system also has a traceability feature that performs at all production stages, from reception through inventory, production and despatch.