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Flexible Automation in Breast Filleting
Breast Cap Deboner 660A
Configurable Automation in Breast Deboning
Traditionally, breast filleting has been performed manually on labour-intensive cone lines. However, with increasing processing speeds and the challenge of recruiting and retaining skilled workers, there is a growing need to automate the deboning process. As the poultry industry shifts toward greater automation, it is crucial to preserve flexibility in processing while protecting both quality and yield. To address these requirements, BAADER offers the flexible Breast Cap Deboner 660A, equipped with customizable configuration options to meet specific automation and processing needs.
Benefits
- Top quality fillet products
- Minimized labour dependence
- Optimized yield performance
- Small machine footprint
- Easy production control
- Predefined production recipes
- Great variety of processed products
- Easy access to the processing tools
- Saddles are removed without use of tools
- Transparent protective doors allow for easy monitoring during production
Configurable Automation Level
The Breast Cap Deboner 660A is a versatile automatic filleting machine meticulously designed to preserve fillet quality and optimize yield. Its automation can be configured to suit either semi-automatic or fully automatic fillet harvesting, offering the highest degree of production flexibility. The fully automatic version of the Breast Cap Deboner 660A seamlessly handles automatic fillet and tender harvesting, along with rest meat and keel bone cartilage (yagen) harvesting. In contrast, the semi-automatic version requires manual fillet harvesting and is not equipped with rest meat and keel bone cartilage harvesting tools.
Automatic Fillet Harvesting or Not?
The choice between automatic and manual fillet harvesting depends on several factors. Experienced workers can tailor the process to the unique characteristics of each breast cap, meeting specific quality standards and various market demands. Conversely, automation uses an integrated measuring station to precisely evaluate the size of each cap, allowing real-time adjustments to the deboning tools and enhancing both efficiency and yield. Therefore, the level of automation should be based on the specific needs and preferences of each processor.
Minimum Labour Requirements
Manual deboning is labour-intensive, increasing reliance on human workers and costs. It also introduces uncertainty with worker attendance and production consistency. Maintaining a skilled workforce requires ongoing training, whereas automatic solutions need only basic tasks like loading products. Skilled mechanics are needed for machine maintenance only.
Automation reduces repetitive tasks and enhances workplace safety. The Breast Cap Deboner 660A offers ergonomic, adjustable loading stations for two workers. Caps are securely conveyed through mechanical tools for skinning, scraping, and cutting on rotating saddles, ensuring a seamless processing transition. Easily removable saddles enable quick, hygienic cleaning.
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Gain Flexibility in Production
The Breast Cap Deboner 660A can process matured and fresh breast caps from 350 grams (0.8 lbs) to 1200 grams(2.6 lbs) W.O.G. weight. Variations +/- 200g (0.4) oz of breast cap weight within one mechanical setting. The machine offers a diverse range of fillet products. Additionally, its fully automatic version efficiently harvests rest meat and keel bone cartilage.
Single fillet
Single fillet, tender attached
Butterfly fillet
Butterfly fillet, tender attached
Tenderloin
Keel bone cartilage (only automatic version)
Fillets can be produced skin on or off.
By-Products
- Breast cap carcass
- Wishbone
- Skin
Leave the Meat on the Fillet
Optimizing yield is crucial, with every gram holding significant value. Thus, the machine features meticulously crafted wishbone knives, designed to preserve more meat on the fillet and minimize waste on the removed wishbone.
Harvest Every Gram of Rest Meat
Traditionally, manual deboning relies on the skill of operators to extract rest meat. However, the fully automatic Breast Cap Deboner 660A excels in efficiently harvesting this residual meat.
Tender Clipping
For the highest quality tender fillets, the Breast Cap Deboner 660A can be enhanced with a tender clipping module. This addition effectively removes any sinew protruding from the fillet, ensuring an appealing product.
Tenders with and without the sinew cut
Less Space at High Speed
One of the most notable distinctions between automatic and manual deboning lies in the required footprint, particularly when operating at high speeds. Manual deboning needs a substantial amount of workspace to comfortably accommodate the task. Conversely, automated tools require minimal space and can operate at higher speeds.
The Breast Cap Deboner 660A occupies less than nine meters of space on the production floor, allowing for efficient utilization of valuable floorspace for other essential purposes.
Breast Cap Deboner 660A Fully Automatic Configuration: 2 workers, 8.8 metres
Manual dual-lane deboning line: 28 workers, 21.3 metres
Easy Process Control
To enhance control and monitoring, the Breast Cap Deboner 660A incorporates a Human-Machine Interface (HMI) control panel located on the plant floor. This user-friendly interface empowers operators to efficiently monitor and adjust deboning process parameters, ensuring optimal performance and yield.
With intuitive navigation and four pre-set recipes available on the screen, production setup becomes fast and simple, especially during production shifts. By utilizing these recipes, operators are allowed to swiftly select the precise machine settings necessary for producing any desired product. These recipes are quick to set up and can easily be modified whenever the need arises. This intuitive feature not only enhances efficiency but also minimizes human errors in machine setup.
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