Managers of modern poultry processing plants must have a complete, clear overview of all their processes to keep control of the product flow from incoming broilers to packed retail products. They need reliable data to drive their decisions.
Processing lines need to convert raw material into high-quality products and deliver the right product to the right customer at the right time. The only way to manage all this is to implement an advanced software platform which provides all possible scope for data collection, traceability, production control, quality control, and performance monitoring (OEE). Marel’s Innova Food Processing Software is just such a platform linking together virtually all machines in the plant. Innova empowers processors in their digital transformation journey to get the most out of their operations.
Increased capacities (up to 15,000 bph) and increased automation go hand in hand with a digital transition. Processors feel the constant pressure to make complex decisions in a really short time, having to match an enormous amount of incoming goods to order requirements.
Moreover, their product quality has to be perfect, otherwise they risk claims and product recalls. Quality Control, food safety and traceability are crucial in this respect. To achieve an effective order fulfilment, IMPAQT software ensures full potential of a Marel poultry production line, bringing availability, performance and quality close to 100%.
All of today’s demands have made it impossible to run a processing plant without having access to digital tools. Innova Food Processing Software is just the right overarching platform to get this done properly.
Operating data-driven processes brings the processor peace of mind. Long-term and short-term planning will be more structured, as all input and output data for production are known. Innova successfully manages to convert this data into carefully defined operations throughout the plant.
“Operating data-driven processes brings the processor peace of mind.”
Food safety benefits from data-driven processing too. Consumers want to know where their meat comes from. Is it a regular broiler or a locally bred, organic, slow-growing chicken? Marel’s automated systems collect product information step by step and add it to the data package that continuously accompanies each product. This reliable way of collecting data enables full traceability throughout the processing plant. Production can carefully be traced and comprehensive information can be printed on the label of each end product. The consumer in the supermarket can see exactly which processes the product has gone through. Marel Poultry solutions, together with Innova Food Processing Software, make this kind of traceability possible.
“The need for information and traceability has grown,” says Roger Claessens, EVP of Marel Poultry. “Consumers want to know what they eat, what its origin is, what the nutritional value is and whether the product is safe. It is a challenge to achieve this with fresh products such as poultry meat.” Data collection is not just useful for informing consumers about the origin of their food. Farmers, processors as well as supermarkets can profit too. Roger Claessens continues, “The data gathered makes processors work in a more efficient and targeted way while maximising the value of their products. Like this, they can get good prices instead of offering discounts. In the near future, artificial intelligence will allow us to produce on Friday exactly what supermarkets need at the weekend during the barbecue season.”
Themes such as traceability, continuous improvement, yield and OEE optimisation can best be handled as part of an operations-wide data solution. Innova software technology has advanced to the point where coupling the big data of a processing plant is a practical reality. Innova MES (Manufacturing Execution Systems) is an example of an operations-wide solution. It links processes for internal logistics (packing and warehousing), planning & optimisation, performance management and quality management. MES provides tracking and monitoring of just about every aspect of every process from ingredients measurement to production reports. By tying it all together for a detailed analysis of each process, MES ensures product flow tracking and full traceability of the products during the production process.
The Internet of Things (IoT) opens new avenues for poultry processors to add even more value. It allows them to automate monitoring as well as diagnostic processes, delivering valuable insight into how to get the most out of machines. This is very useful when implementing smarter processing and predictive maintenance. Remote diagnosis via IoT makes maintenance work more efficient and sustainable while saving local labour too. By using IoT, each and every day we can save one symbolic Boeing 737 airplane flying Marel engineers around the world.