1 Apr 2007 ... ”Fish processors can expect to see an increased effort to provide new and ....
even more advanced processing equipment that will result in ...
Advantage New developments in the fish processing industry April 2007 - Volume 1
”Fish processors can expect to see an increased effort to provide new and innovative solutions to their production challenges from Marel Food Systems” Hörður Arnarson, CEO Marel Food Systems
M e m b e r s o f ma r e l f o o d s ys t e m s
C O N TE N TS
2 Expanded operations benefit customers 3 Full solutions from a single source 4 Growth leads to expansion in the Faroes 5
Expanded operations benefit customers
The extra mile
6 Loads more output at less cost 7 New MPS software – more is better 8 SensorX bone detection 9 Automatic deheading, tail cutting and infeed in one 10 Portion cutter batches to fixed weight in trays 11 Record flowline sales in Iceland 12 New ProLine graders in action 13 Lightweight screen for shrimp grader 14 Marine Harvest and Marel work together 15 ScanCombinator self-adjusting multihead weigher 16 Impressed by IPS3000 17 Turning to Scanvaegt for new solutions 18 Shrimp for Japan 19 Double functionality for sea bass and sea bream 20 Gentle, automated whole fish processing 22 Intelligent batching of dried salted cod 23 Service is a collaborative partnership 24 By-catch separation at high capacity
Hörður Arnarson, CEO of Marel Food Systems.
The merger of AEW Delford, Carnitech, Marel and Scanvaegt into one group – Marel Food Systems – with a unified sales and service network offers fish processors new and innovative solutions to their production challenges As some of the world’s leading manufacturers of fish processing equipment the four companies that make up Marel Food Systems have provided innovative and advanced equipment and turnkey solutions to all major fish producers over the last decade. ”Fish processors are continually looking for ways to improve their products,” says Hörður Arnarson, CEO of Marel Food Systems. ”In bringing together four innovative companies we have created a strong player that can meet the demands of our customers with sound, dynamic product development and cost efficiency through economies of scale.”
Covering all aspects of processing The product range has expanded and covers every need in the fish processing industry from deheading, trimming and grading through to further processing of hot and cold ready-made products. “It is necessary to offer an extensive product mix to meet the needs of high-tech food processing
companies. It is not enough to offer one machine; companies must be able to provide total solutions,” says Hörður. ”Together, AEW Delford, Carnitech, Marel and Scanvaegt offer high quality equipment and turn-key solutions that cover more of the value chain than they could each offer before.”
Dedicated to innovation Innovation has been the driving force behind the success of each brand, a strategy which Marel Food Systems continues to pursue. ”We have been committed to vigorous product development in order to meet our customers’ demands,” says Hörður. ”Fish processors can expect to see an increased effort to provide new and innovative solutions to their production challenges. The strength of Marel Food Systems lies in the capability to respond quickly to emerging needs and provide a strong global service network.”
Full solutions from a single source Companies in the food industry are on the lookout for solutions designed from the outset to be highly effective, integrated systems. To reap the full benefits of these, an increasing number of plant operators are moving toward systems sourced from either one single supplier or a very limited number of experts. The partnership between AEW Delford, Carnitech, Marel and Scanvaegt has created exactly this kind of high-impact singlesource supplier of processing solutions for the food industry.
Companies that wish to build a new processing facility, or refurbish an existing production hall or line, want to work with one supplier that can deliver the entire system, rather than having the trouble of cobbling together machinery from several different suppliers. “We see more and more companies wanting to deal with one single supplier, who is responsible for the development and execution of a turnkey project,” says Scanvaegt’s Business Manager, Fish Solu– tions, Chris Bjerregaard, and continues “Having just one single supplier, provides our customers with clear-cut advantages. Firstly, it minimises any potential for error in the interface between equipment. Secondly, it paves the way for a better, safer total solution and more reliable installation of the processing line.”
Combining expertise in every food segment Food processing companies normally look for integrated solutions on a case-by-case or product-by-product basis. Sometimes, however, this involves using multiple suppliers because each can provide them with indispensable expertise in a particular field. In such cases, expert suppliers whose capabilities are already well integrated can provide additional benefits in
the form of new ideas that arise as a result of expert discussions. Marel’s Senior Manager, Seafood and Aquaculture Soltions, Runar Birgisson points out. “The close partnership between the four companies also means that we pool our R&D resources. This means we can develop even more advanced processing equipment that will result in big-time benefits for our customers’ productivity.”
Meeting all processing needs Poultry, meat and fish processing experts from AEW Delford, Carnitech, Marel and Scanvaegt are often called upon to provide specialist consultancy services throughout the food processing industry. Marel Food Systems has a comprehensive portfolio of equipment and solutions that are fully capable of meeting the entire spectrum of requirements for portioning and traceability in food processing facilities. These include: • Graders and batchers • Multihead weighers • Portioning machines • Labelling systems • Traceability systems • Quality inspection systems • Flow lines • Robot solutions
Growth leads to expansion in the Faroes – with interlocking salmon solutions from Marel Food Systems
Salmon processors in the Faroe Islands have been enjoying the global upswing in the salmon industry. This includes P/F Faroe Salmon Processing, whose operations cover the value chain from farming and slaughtering to further processing and product sales. Growth leads to expansion, which led P/F Faroe Salmon Processing to Marel Food Systems to look for ways to boost both processing capacity and performance. Today, Marel Food Systems has four primary brands that complement one another: AEW Delford, Carnitech, Marel and Scanvaegt. This puts the company in the position of being a single-source supplier that offer the bestof-the-best in processing solutions for the food industry – customers select from an expansive range of integrated brand solutions to ensure peak processing performance.
A single-source supplier that can offer the best-of-the-best in processing solutions for the fish industry.
Interlocking brand solutions The new turnkey processing solution will go online in the summer of 2007, equipped with a range of interlocking Marel Food Systems equipment. Raw material is pre-graded at the slaughterhouse on Marel’s Salmon Packing Grader before being transported and weighed-in at the further processing plant. From there, it goes through a Carnitech Salmon Filleting machine and is then automatically trimmed in a Marel Intelligent Trimming Machine (ITM). Next, fillets pass through Carnitech’s pinbone removal system, and a Carnitech skinning machine
and manual brown fat removal system. Fully trimmed fillets are then portioned on two Scanvaegt portion cutters. Yield control is handled with Marel Hopper Scales and MPS software. Fish portions are vacuum-packed and boxed. At a later date, automatic batching and presenting of portions using robotics from AEW Delford is anticipated, but already this solution is lining up as one of the most sophisticated salmon processing solutions in the world.
The extra mile The commitment to go that extra mile is the experience that what makes Carnitech in Seattle the natural supplier of processing equipment for Bear & Wolf Salmon Company.
Bear & Wolf Salmon Company is one of the biggest producers of wild caught salmon in Alaska, bringing superior products to the international market through custom processing lines at their facility in Cordova, Alaska.
Excellent support
Investing in numerous projects
into several projects at the plant in Cordova, acquired when Peter and his partner Sean O’Leary established the company in 2002. As Peter Kuttel recalls, ”The Cordova plant was in dire need of modification before we could possibly re-open it. The job was offered to Carnitech because I knew that they are reliable, always willing to go that extra mile to ensure that their equipment is delivered and installed on time. The on-site team has been outstanding and have always been very responsive to providing support to our facility, from next day spare parts service to sending technicians to solve onsite problems.”
”Bear & Wolf is one of our most valued customers and we are happy to have such rewarding and mutually beneficial relations with them,” says sales manager from Carnitech in USA, Frank Flem. ”Since the establishment of Bear & Wolf Salmon Co. in 2000, we have done one or more projects every year, including a new raw material handling system for the receiving area, new heading and gutting lines as well as improvements of the in-feed to the canning area.” He continues ”Last year we installed a new Salmon filleting line, and a new Ikura line for the salmon roe, and this year another filleting and Ikura line is in production. The lines will be installed by the mid-May, ready for the upcoming salmon season.”
Carnitech’s co-operation with Peter Kuttel, co-founder of Bear & Wolf Salmon Co., began in 1998 with a successful remodelling of a filet factory onboard his vessel »Northern Victor«. This was the first step in the relationship, which since then has evolved
From the left: owner Peter Kuttel, Area sales manager at Carnitech in the USA, Frank Flem, and owner Sean O’Leary
A ’one-stop shop’ Based on a long tradition of supplying complete plants for the processing of seafood, Carnitech has developed broad competence and expertise in the field of wild salmon. In-house engineering and close co-operation with customers enable them to supply both traditional and high-tech design. Peter Kuttel stresses their ability to act as a ’one-stop shop’ in providing efficient turnkey solutions, from design through to construction and installation. ”The employees are very professional and knowledgeable in their approach to providing processing solutions. They demonstrate attention to detail as well as quality of work, not to mention the ability to customize solutions to our various processing activities and needs,” says Kuttel.
Future key role Over the years the production at Bear & Wolf has kept on growing. When asked
”Carnitech’s on site team have been outstanding and have always been very responsive to providing support to our facility.” Peter Kuttel, owner of Bear & Wolf Salmon Company
about future goals for the company, Kuttel makes a point of including Carnitech. This year’s goal is to improve product flow and handling, throughout all the processing lines. Kuttel remarks, ”Our customers are continually asking us to come up with new value added product forms. Carnitech has and will continue to play a key role in this development.”
Loads more output at loads less cost AEW Delford’s new Intelligent Portion Loading (IPL) Robot uses vision technology to accurately identify the position and orientation of incoming portions, enabling it to lift, turn and transfer them – gently, quickly and accurately – in varying configurations. The IPL robot can load fresh fish portions into trays or thermoformers and added value products like breaded portions into final retail packs including boxes. Whole, fresh fish can also be handled in singles or
multiples. Other applications include automatically loading the infeed belt of a freezer in order to optimise the available space thus saving labour and energy costs. For high volume applications, the single vision and control system can handle up to six robot heads, each of which can perform various tasks and certain grading options and, thanks to 99 product programme memories, product changeovers can be made quickly and simply.
Features • Unique pick-up head enables portions to be loaded gently and accurately into trays or thermoformers • Vision technology provides various grading options such as size or shape • Available with up to 6 loading heads depending on production requirements • A range of fast change pick-up heads is available for different products • Quickly removable product contact parts for easy cleaning • Operates stand-alone or can be integrated into a wide range of manual or automatic production lines
With all Production Performance Indicators at their fingertips, plant managers are able to optimize processing quality and efficiency.
New MPS software – more is better Expanded features and functionality greatly improve production monitoring & control Marel has just released its next generation MPS Production Software. This software is already up and successfully running at two locations in Iceland. MPS monitoring and control software immediately became an indispensable component in modern food manufacturing when initially released in the mid 1990s. These earlier MPS versions have been installed at close to 900 locations worldwide.
Optimizes production The primary function of the next generation MPS software is to monitor and control all processing and production operations, including weighing, grading, portioning, trimming, packing, labeling, inventory, shipping, receipts, quality control, planning, ordering, order packing, and remote servicing, giving 100% traceability. This traceability feature performs at all production stages, from reception through inventory, production and dispatch.
The system allows users to follow the overall production process in real-time. This makes MPS a valuable decision-making tool: with all Production Performance Indicators at their fingertips, plant managers are able to optimise processing quality and efficiency. MPS software therefore plays an essential role in significantly reducing giveaway while increasing throughput and yield, improving product quality and positively impacting profits. It is also a tool to effectively monitor and improve employee performance.
Short learning curve The next generation MPS includes a new and easy-to-use interface. The software has a very short learning curve, and supports the full range of users: individuals at all levels of operations can easily access plant and processing data using a simple point-andclick navigation tool.
MPS data analysis tools provide plant decision makers with immediate access to detailed, real-time plant information. The production history provides information regarding machines utilized, shifts, users and their capabilities, quality records and links to continuous process data.
Web reports and integration The system is equipped with dynamic integration capabilities that have been effectively implemented in various ERP system, for example Microsoft Dynamics NAV and SAP. It also has extensive reporting capabilities to handle even the most complex reporting requirements. In addition, reports from the system can be published in realtime on the Internet for easy access by management and customers.
Boosts the image, value and potential of fish blocks
SensorX bone detection
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The batches containing detected bones are delivered to an inspection station that comes equipped with its own high-resolution display terminal, which highlights the bone location in color.
Today consumers are growing increasingly concerned with foodsafety issues. This includes demands for boneless fish products. Processors who are able to provide fish blocks that meet high, boneless standards have a competitive advantage. This inevitably boosts the image of their fish blocks, increases their value and ultimately sparks interest in using this raw material in high-value products. sensorX innovation Marel responded to this food-safety need by developing the SensorX pinbone-detection system that efficiently analyses fish blocks for bone content. The solution was originally developed for fish fillets, and has been successfully operating in processing plants for over three years. This automation, which does not rely on human inspection, now brings boneless standards for block material to a new level. “Batches of block material pass through the SensorX where it is scanned for bones using low energy X rays. Bones and bone fragments are graphically shown in color on the equipment’s display. A signal is then
sent to a discharge unit that automatically removes the batch containing bones from the material flow,” says Hannes Gunnarsson, fish consultant at Marel.
if all bones were removed. Powerful Marel MPS software tracks each batch to individual trimmers to reveal performance statistics.
Greater food safety bone removal The batches containing detected bones are delivered to an inspection station that comes equipped with its own high-resolution display terminal, which highlights the bone location in color. Using this as a guide, an operator removes the remaining bones, and places the material on a conveyor that returns the batch to the SensorX, which performs another inspection to determine
SensorX consistently monitors the blockmaterial. It is designed to be integrated into the whole food processing cycle. “The success of Marel’s bone detection technology has greatly increased food and product safety,” says Hannes. “At the same time, a higher-quality boneless fish block expands potential for further processing into higher-value categories.”
Automatic deheading, tail cutting and infeed in one “Ct 2620 is the first system to combine head and tail cutting with automatic infeed to a filleting machine, enhancing efficiency as well as improving end product quality.” Knud Nielsen, Sales Manager, Carnitech Salmon Division
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the deheading machine performs in 4 stages 1. The salmon is placed in the infeed carriage and the operator activates the machine 2. The head is cut off by a guillotine blade 3. The tail is detected by a sensor and cut off by a circular cutter 4. The salmon is automatically fed into the filleting machine
Designed for automatic deheading and tail cutting of salmon, the new CT 2620 minimises product handling and contributes to a less labour intensive production. Operation costs are reduced, and yield is increased due to better control of deheading, tail cutting and filleting processes. The deheading machine is capable of handling up to 15 fish per minute and makes 11
a uniform cut. Operating the CT 2620 is easy, and no adjustment is required from one fish size to another. The unit is designed for a perfect fit with the CT 2630 filleting machine. Automatic infeed makes for improved and more uniform filleting results as does tail cutting prior to filleting.
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Portion cutter batches to fixed weight in trays Capable of batching 120 (dual lane) salmon fixed weight salmon portions, the Cut ‘n Batch concept from Scanvaegt and Marel is a new way of efficiently automatically cutting, weighing and tray loading salmon portions with only two lane operators.
Benefits • Intelligent tray loading – reliable automation for a simple packaging task • Short payback time through reduced labor costs • Less material handling 1 0
• Provides consecutive salmon portions with equal colour and width in each batch/tray/pack • Exact weight on the entire batch (not per piece) • No need for weighing machine or grader/batcher • Provides gentler handling than a grader/batcher solution • Higher capacity than an individual weighing line • Automatic tray packing
The Portion cutter controls the entire line by first scanning the product and determining where the cuts are to be made to produce the portions for the fixed-weight trays. A pre-defined weight and number of cuts will make up each tray. When the portions (e.g. 2 per 250 g) leave the portion cutter they are separated by a small gap that indicates the fixed weight portions.
The fixed weight portions continue into a Marel Quickloader that delivers the portions automatically into trays, by a quick backwards move of the conveyor that makes the portions drop gently into the trays – maintaining their shape and style.
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7 2
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Head/trim
Tails
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Trayholder
5 To traysealer
1. 2. 3. 4. 5. 6. 7.
ScanPortioner B36 with Cut n’ Batch Head and trim reject Tail reject Line divider Marel Quickloader Tray dispenser ScanWi 411 Scale (3 kg)
“The only rule is to stay competitive”
Record flowline sales in Iceland Last year was the best ever for sales of Marel flowline equipment in Iceland, the company’s home market and one of the world’s most experienced and knowledgeable fishing and fish processing societies. These flowlines are an important reason why the value of fish products in Iceland is rising despite lower catch quotas. “Processors in Iceland understand more than ever that flowline systems and solutions, which Marel has innovated and developed over recent years, are the main reason why they are still highly competitive. Iceland has some of the best fishing grounds, but processors must safeguard that quality all the way to market,” says Guðjón Stefánsson, fish consultant at Marel´s Business Center.
Enhancing performance in every aspect Flowline solutions from Marel lower costs, increase efficiency, reduce overweight, improve utilization of higher-priced items, guarantee 100% traceability, maximise quality control, enhance ergonomic configurations and allow management to monitor and control all processing operations in realtime. “Marel plays a fundamental role in enhancing every aspect of processing performance – and power,” says Guðjón. “For example, the Marel company has developed filleting and trimming flowlines that track yield and quality from every worker. On top of that, payback is even faster than most processors would allow themselves to imagine.”
Continual innovation of solutions Recent innovative solutions from Marel include being able to grade specific product sizes for packing fresh, while other sizes are automatically transported to further processing such as pan freezing. Another
innovation involves moving fish from flowlines directly to a Check Bin Grader that automatically batches into retail packaging according to user-defined parameters – with a high precision of +/- 1-2 gr, which means virtually zero giveaway. This system also eliminates the need for manually weighing portions. “Iceland is a small country, so everyone knows when a new innovation is having a real impact on another processor’s performance.
Many follow suit, because they are not about to be left behind in the competition,” explains Guðjón. “This is also becoming true on a global scale. Processors must keep up to date technologically or risk being left behind in quality and efficiency.” Guðjón continues, “Part of our job at Marel is to show how innovations can positively affect operations large and small. Competition is competition – the only rule to stay competitive.” 1 1
Our flowlines ensure that “quality in” also means “quality out.” Guðjón Stefánsson, fish consultant at Marel’s Business Center.
New ProLine Gra in action The ProLine Grader series feature a versatile suite of standardized modular options and add-on components, designed to fulfill all general grading and batching needs. This innovative concept gives processors the flexibility to select a grading-solution combination that matches individual operating environments.
Providing processing flexibility Fiskkaup was one of the first Icelandic producers to install the new ProLine Grader at its Reykjavík processing facility. The company annually processes fresh cod and haddock fillets and loins, salted cod, saithe, ling, kusk and frozen fillets from approximately 4,000 tons of raw material: 3,000 tons from own boats and 1,000 tons from Icelandic fish markets and other vessels. 1 2 Diverse production such as Fiskkaup’s needs processing flexibility, which is precisely what the ProLine Grader provides. The small and the medium cod are used for fresh fillets and loins that are air-freighted to market. Large cod goes into salting, while haddock is airfreighted daily. Fiskkaup’s other products are salted, lightly salted or frozen lightly salted. ”We needed a new grader to use for IQF products coming out of our Dantech Spiral Freezer. We also needed the option of grading smaller fish portions, tails, fillets, roes and other IQF products,” says Baldvin Ingibergsson, production director at Fiskkaup. ”The new ProLine Grader fits our needs perfectly and in the time it has been operating it has proven to be simple to operate, compact and flexible.”
Pick and choose
”The new ProLine Grader fits our needs perfectly and in the time it has been operating it has proven to be simple to operate, compact and flexible.”
Baldvin Ingibergsson, production director at Fiskkaup.
Marel’s open-end design gives processors the ability to fulfill their individual needs. Working with Marel consultants, the right combination of standardised ProLine components is selected to tailor-match a processing operation, for example platform size, gates, divisions, batching bins and chutes. “The ProLine’s flexibility also gives us the future option of adding or changing modular components at will. This is the best of both worlds,” says Baldvin.
ders Great hygienic design The main structure of the ProLine graders is nontubular: there are very few horizontal surfaces. “It’s very easy to put the ProLine graders into a washing position that gives access to all parts,” says Baldvin. ”This hygienic design was one of the major factors in our decision to go with ProLine. We can easily do a complete cleaning job in very short time.”
Lightweight screen for shrimp grader
Flexible and easy to operate
Long-term dependability at low cost
The ProLine graders are easy to set-up and operate, and have batching capabilities – including intelligent batching. They are also equipped with a user-friendly M3000 graphical interface that greatly reduces the possibility of human error, and an innovative belt design improves precision and handling.
To further improve the operational reliability of Carnitech’s shrimp grader type 1014, we have developed a new lightweight screen. Here-and-now savings as well as prolonged operating life makes this an obvious choice.
In addition to the economical price-tag for value, the new ProLine Graders are extremely easy to clean, thanks to the all-new openconstruction that replaces tubular design.
Features • Weight reduced by 30 kilos per set of screens • Composite materials for less corrosion • No lubrication • Adjustable attachment between screen railing and suspension • Considerable price reduction due to cost effective manufacturing techniques
Ocean Prawns about the new Carnitech screen: ”We are very pleased with our new set of screens which has been in operation onboard »Atlantic Enterprise« for almost a year. Because of reduced weight, the load exerted on the bearings has decreased, meaning that maintenance costs are lower.”
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Marine Harvest and Marel work together MPS Optipack ensures that customer product requirements are properly fulfilled.”
Unique solution Marel has focused on salmon solutions in their R&D efforts, bolstered by customers returning for additional or new solutions. In 2004, Marine Harvest Ryfisk contracted to buy Marel’s first Intelligent Trimming
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Marine Harvest is a leading seafood company that produces about onethird of the world’s farmed salmon and trout. The company started collaborating with Marel almost a decade ago when it installed two salmon packing graders. Performance exceeded expectations and a third unit soon followed. 100% increase In 2006 Marine Harvest signed a watershed agreement with Marel to purchase three Sure Track Salmon Grading Systems (STS) for its plants in Fort William, Scotland and Ulvan and Ryfisk in Norway. After the first system was installed in the Fort William facility throughput increased by a massive 100%. One shift now produces what previously took two shifts. The other two STS systems are scheduled for installation next summer and in early 2008. “The main benefit is the hugely increased throughput in grading and packing salmon,” says Rúnar Birgisson, Senior Manager, Seafood and Aquaculture Solutions at Marel’s Consulting Center. “A second benefit is that the same software will be used in all three plants, which simplifies KPI comparisons between the sister plants. In addition, the
“The main benefit is the hugely increased throughput in grading and packing salmon.” Runar Birgisson, Senior Manager, Seafood and Aquaculture Solutions, Marel
Machine (ITM), even before any design work had begun. Working in close cooperation, the two companies developed and expanded the ITM’s capacity to include optimal decisionmaking for pre-rigor salmon fillet processing. One of the system’s main competitive benefits is its ability to process various
trimming constraints simultaneously: it makes the optimum decision for each fillet based on color, quality, size, shape and other user-defined parameters.
Ongoing strategy The partnership effort surrounding development of the ITM has proved invaluable. Marel has a product that fulfills an industry need, while Marine Harvest is able to immediately implement an innovative solution – a solution that is unique on the market. This type of cooperative effort is an intrinsic part of the way Marel innovates solutions. It is an ongoing strategy that has proved effective time and again, and will continue to be implemented.
Automatic Feeder Adjustment technology comes standard with all ScanCombinator multihead weighers.
ScanCombinator self-adjusting multihead weigher
Scanvaegt’s series of multihead weighers, the ScanCombinator, now comes with the unique Automatic Feeder Adjustment technology (AFA) that ensures a consistent high flow of products to the weighing unit, greater processing accuracy and all time low maintenance costs. The key to weighing accuracy and high production capacity is an effective vibratory
feed system. To make sure the vibratory feeders operate at maximum efficiency, it is crucial that each feeder vibrates at its own specific resonance frequency at all times. This frequency changes over time, however, due to wear and tear in the feeder system as well as normal fluctuations in temperature and humidity. The unique AFA technology from Scanvaegt therefore automatically ensures that each individual feeder vibrates at its own unique resonance frequency.
All time low maintenance costs The AFA technology has been developed by Scanvaegt’s R&D department on the background of a clear wish from existing customers. “The most important factor for our customers is that the multihead weighers are performing consistently and with as little downtime as possible,” says Director of Development at Scanvaegt Henrik Skyum. He continues, ”the multihead weigher is able to optimise the resonance frequency of all its vibratory feeders in less than 30 seconds ensuring a consistent high capacity.”
designed specifically for wet and sticky products The design of the Scanvaegt multihead weigher ensures that soft, wet and sticky products like mussels and cooked shrimps as well as other hard-to-handle products are moved to the weighing unit as smoothly and rapidly as possible – and does away with feeder system blockages.
built to last The ScanCombinator is perfected for maximum reliability and built to last – e.g. all parts of the multihead weigher are in stainless steel with various choices of surface of the radial feeder system. The hopper and the hopper gates are driven by step motors, ensuring high-speed operation, flexibility and minimum maintenance. The ScanCombinator features excellent hygiene with an open construction and easyto-clean sloping surfaces. It has an intelligent user interface with high-quality colour touch screen making it easy to operate.
FEATURES • extremely fast self-adjustment – it takes less than 30 seconds to optimise the frequency of all 10, 14 or 18 vibratory feeders • easy to use – no need to give operators any special training – just push a button • driver frequency is far more accurate than when using mechanical adjustment • Unaffected by any fluctuations in main power supply.
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Impressed by IPS3000 As part of a company strategy aimed at higher quality and increased efficiency, Kritsen, Breton specialist in smoked salmon, has bought no less than six IPS3000 slicers.
Barely released from the development department, Carnitech’s most recent venture in fresh slicing greatly impressed Kritsen at the 2005 SPE show in Brussels. The first slicer to integrate vision technology, the IPS3000 has since become a huge success in the French market. A success also brought about by the close co-operation between Carnitech and their distributor in France, Lassoudry SAS in Evry.
Obtaining a higher profit
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In the production of high-quality products such as the Kritsen Red Label, fixed weight and a fixed number of slices on each retail plate is paramount. ”When it comes to slice weight and thickness as well as the number of slices on each plate, the IPS3000 offers a great number of options. The cutting profile of each fillet is calculated to meet the exact specifications of the final product, and for Kritsen this means they can produce their superior quality Red Label party packs with a higher profit on each fillet,” says Knud Nielsen, Sales Manager at Carnitech.
Intelligent slicing Slicing parameters are optimized automatically and slicing takes place at angles ranging from 8° to 30°. ”The slicing process is controlled to an
Kritsen is one of the leading value-added producers of salmon in Europe, with an extensive portfolio of smoked salmon and seafood delicatessen products. In recent years, they have invested strongly to increase efficiency in all their operational units in Brittany.
unprecedented degree. Once the requested output has been programmed, an exhaustive calculation process takes place. Knud Nielsen explains and elaborates, ”The intellligence of the system allows for a definition of the weight of each slice, the number of and position of slices on the plate, as well as the width and length of each slice – the latter being of great importance to Kritsen. It is an efficient, automatic solution, saving manpower and eliminating manual handling of high-priced products.”
Timing is everything According to Knud Nielsen, the timing was extraordinary. There was a perfect match between problem and solution, and the
prospect of a 10-15 % yield increase left Kritsen with no doubts that they should take the plunge and buy no less than four slicers not even released onto the market. ”When they first saw the machine in Brussels, all the software applications were not fully developed, so Kritsen knew what they were letting themselves in for. But there have been absolutely no regrets, and co-operation has been mutually beneficial. They let us do all the necessary testing at their production facilities in Landivisiau, and today they have two IPS3000 lines – each with three integrated slicers,” says Knud Nielsen.
France - the ideal market The IPS3000 slicer from Carnitech has become such a huge success in France because salmon producers are able to meet requirements specific to the French retail industry at a considerably lower cost. Up till 80 % of the slicers sold are in use in France. Carnitech has been in this market for several years, but the IPS3000 has clearly strengthened the position in this part of the world.
The main advantage is the vision system generating accurate analysis of fillet shape and size
Developed in close co-operation with Marel, the IPS 3000 provides significantly improved performance in the production of retail packs of fresh sliced smoked salmon.
The slicing angle is automatically altered to obtain the correct weight on each slice
A long-time Scanvaegt customer Portuguese Miradouro/FrioPesca knows where to turn when in need of innovative and trustworthy solutions for their production facilities, be they for onboard fish processing, sorting of frozen fish or for packing of vegetables. Each time a new solution has been installed in one of the FrioPesca operations it has resulted in huge savings and production efficiency .
Turning to Marel Food Systems for new solutions
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frozen efficiency at frina
bagging of vegetables at frioPesca
Huge savings on reduced giveaway
In the beginning of the 1990’s FrioPesca bought Frina – a processor of frozen fish near Lissabon. At the time of purchase Frina already utilized Scanvaegt equipment. So when some years later they needed new equipment for batching the frozen fish, they naturally looked to Scanvaegt for a new solution – and they have been loyal to the company ever since. The Managing Director Mr Carlos Leitão explains “the equipment is very reliable and easy to operate. We rarely have any problems – but we know from experience that the Scanvaegt service is prompt when needed. We have a service agreement covering everything from spare parts to preventive maintenance visits – and are fully happy with the set-up.” About the recent changes in connection with Marel buying Scanvaegt, Mr Leitão is satisfied with the fact that the to him well-known set-up in Portugal is being kept.
Using multihead weighers from Scanvaegt has radically changed production of frozen vegetables at FrioPesca. The company installed its first multihead weigher in 2004. Since then, the company has invested in its second unit – and is aiming at a complete focus on supplying the retail industry with bagged products.
The first multihead weigher from 2004 increased FrioPesca’s bagging capacity from around 30% to 65% of total frozen vegetables production. In May 2006, the company commissioned its second Scanvaegt ScanCombinator 5418 and bagging line, and this increased quantity and the bagging capacity tremendously, meaning that more than 90% is now packed in retail bags. The daily throughput on a oneshift day amounts to more than 20 tons. “We installed the first multihead weigher and bagging line in order to comply with weight requirements and reduce giveaway. We now only have 0.8–1% giveaway in our bags, which has given us savings in overweight of €95.000.” ”This,” Mr Leitáo explains, ”equals 2 % in saved overweight. In addition, we have reduced costs, mainly because of the higher capacity using the same staff. We estimate the payback time of each multihead weigher line to be approximately 2 years,” he adds.
On the lookout for a multihead weigher to pack vegetables, such as broad beans, green beans or pepper in 400 g, 1 kg and 2.5 kg bags, the company invested in a solution from Scanvaegt, which in 2004 was gaining a foothold in the multihead weigher market. Carlos Afonso Leitão explains, “The Multihead from Scanvaegt had a better speed and performance than other machines that we looked at from some of the leading suppliers. We also chose the Scanvaegt multihead weigher because of its easy integration with other machinery in our production – such as that from CFS”.
Shrimp for Japan High expectations of Carnitech’s new Japan line on board Qaqqatsiaq have been met. Royal Greenland is now able to maintain the same capacity with half the crew.
Raw, high-quality shrimps for the Japanese market – a delicacy indeed – and the type of product in which Royal Greenland hopes to increase its stake in the future. They estimate that over time, the upgrade of their existing line will be able to boost the production of Japan shrimps by 40%.
A labour-intensive operation
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”On our new semi-automatic line, each individual employee can produce twice as much as before. In practice this means that we can maintain the existing maximum capacity with half the crew. This is extremely important to us given that the processing of shrimps for the Japanese market is such a labour-intensive operation. Until now we have not had the resources on board to exploit the available capacity and produce the quantities we wanted, but since one operator can now handle as many as three stations at once, we are able to run at full capacity,” says captain of the ship Torbjørn Joensen.
Captain Torbjørn Joensen: “With the upgrade, we can maintain the existing maximum capacity with half the crew”.
Qaqqatsiaq is one of the many Royal Greenland factory trawlers Carnitech has equipped over the years
Carnitech weigher hopper system allows for continuous weighing out, independent of the operator. Secondly, a case erector with automatic feed to the weighing tables has been positioned right in front of the line, saving valuable time previously spent on fetching cases farther away. Thirdly, automatic sealing and labelling of the cases also saves time, so the shrimps get to the freezers much faster. ”Between them, these optimising factors result in a better, quicker flow and far more user-friendly weighing out,” says production manager Claes Hjælmeland.
More accurate grading
Raw shrimps for the Japanese market - a delicacy in which Royal Greenland hopes to increase its stake in the future
Quicker production flow A number of optimising factors have made the improvements possible. Firstly the
Other production areas have also been given an optimising lift. More direct in-feed for the shrimp graders makes for an even distribution on the screens and thereby more accurate grading, which was the specific requirement of Royal Greenland. Here, emphasis is on quality rather than capacity increase, but according to Søren Hansen, area sales manager at Carnitech, the new infeed system also opens up the possibility of higher capacity while maintaining existing grading accuracy.
By-catch separation twice as good Separation of by-catch has become easier and more efficient onboard Qaqqatsiaq. The new unit from Carnitech is twice the size of traditional separators and provides twice the capacity. A semi-automatic tilting system
generated by an electrical cylinder makes it easy to adjust the angle of the conveyors and contributes to the improved user-friendliness of the machine. ”By and large we are pleased with our new easy-to-clean separator – with its user friendliness and its stabilising mechanisms which compensate for lopsidedness. Besides, we expect the operating system to provide us with a longer service life, since the plastic sprocket has been replaced by a robber roll,” says Claes.
Increased efficiency in packing area Qaqqatsiaq is the first factory trawler to invest in Carnitech’s new, larger magazine for Seaward case erectors in its packing area. With space for 600 plano sheets at a time and improved feeding to the case erector, operating times have become noticeably longer and there is less interruption of production caused by jamming during infeed. Combined with automated label application, Royal Greenland has thus increased production efficiency considerably with the new magazine. ”An additional efficiency and capacity increasing feature in our packing area is an extra strapping line, also supplied by Carnitech. It provides reserve capacity at peak load or in the event of failure on the other lines. At the end of the day, this means an overall capacity boost, since the risk of a complete production shutdown is now negligible,” says Claes.
Double functionality for sea bass and sea bream Sea bass and Sea bream Fish Farm in Turkey
Whole fish grading and packing, as well as filleting lines for fresh and IQF frozen pieces – with 100% traceability
Sea bass and sea bream now processed and packed whole or filleted, fresh or frozen, for convenient consumption Sea bass and sea bream are excellent table fish, but many modern kitchens consider their preparation time consuming. Additionally until recently it has been virtually impossible for restaurants, caterers and supermarkets to find these species size-graded and portioned. This is changing. Marel has developed a new processing line concept for farmed Sea bass and Sea bream, that incorporates double functionality: whole fish grading and packing, as well as filleting lines for fresh and IQF frozen pieces. Both capabilities include 100% traceability from catch to packing.
it is weighed on an M2200 scale and automatically registered in Marel’s MPS production software system. Each container of fish is assigned an identity number, which includes information such as species, date, harvesting location, etc. A printed label is automatically applied onto the box. This label is scanned before fish is transported to a high-speed grading unit. The grader batches the product according to pre-defined parameters for packing into boxes. Here, the system can be programmed to remove predefined sizes that are transported to filleting. The raw material grader is equipped with a special infeed to maximize throughput, and can also be used with intelligent batching to minimise overweight in each pack. A final label is then applied in the packs to ensure 100% traceability.
Whole fish processing When raw material arrives at the plant, marked with date and location of harvest,
Marel High Speed Sea bass / Sea bream intelligent batching Grader for up to 150 pieces pr/min
before entering a descaler, weighed again before deheading, and then sent to automatic filleting. All yield points on the fillet are measured and registered by Marel MPS software. This data can then be accessed in real-time by managers, who monitor and control operations and performance by individual operators. After filleting the fish is fully trimmed and sent to a Dantech IQF to maximise product quality. It only takes a few minutes from the time the raw material enters the processing line until it is frozen. After freezing the fillets are individually graded on a Marel high speed IQF grader, packed and boxed with labels containing all necessary information. When the product is ready for shipment – either frozen or fresh fillets or fresh whole fish – the pallets and boxes are scanned out of the MPS final stock inventory via a wireless scanning system to ensure full traceability.
Filleting The fish is first size graded and weighed
Marel in-weighing system prior to filleting – an important link in yield monitoring of the total process.
Sea bass and Sea bream packing grader with checkweigher and label printer.
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Gentle, automated whole Handles up to 120 fish/min With a processing capacity amounting to 120 fish every single minute, the Superior Salmon Solution and the ScanBatcher 4700 provide virtually unlimited processing opportunities for producers of whole salmon. The processing line is capable of carrying out multiple jobs simultaneously, with 4–5 different qualities and 6–8 sizes per quality.
“Since this concept was launched in 2006 we have seen a tremendous interest and feel that we have managed to really create a “superior salmon solution” that meets the expectations of our customers”, says Chris Bjerregaard, Business Manager, Fish Solutions at Scanvaegt International. He continues, “After a period of experimenting with different technologies resulting in some record breaking installations we decided to analyze what kind of solution and general way of thinking the customer would appreciate the most. Naturally we looked internally, but also externally to improve our solution significantly from other possible solutions”.
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1. Manual infeed and quality control. 2. All conveyors feature an open, easy-to-clean design, and are made of the finest materials available – both 304 and 316 stainless steel for standard equipment, and Intralox belts wherever suitable. 3. Dual-line infeed to gutting machines. 4. Automatic infeed system for BAADER 142 gutting machines. 5. BAADER 142 gutting machines. 6. Quality inspection after gutting. 7. Manual gutting line using a Scanvaegt quality dispenser returns fish into the system after bypassing the automatic machines. The ScanBatcher 4700 ensures that downgraded products are traceable. This gives a complete overview of the flow into the different machines and manual functions. 8. Quality inspection after gutting. 9. The ScanBatcher 4700 can be equipped with a number of different bin types to meet specific needs. 11. Automatic head to tail juxtaposition with the TurnBin 180) 12. The Scanvaegt check weighing system recognises the actual net weight and gross weight of the boxed products. These can be delivered in dynamic, start/stop and manual versions. Information provided by the grader and ScanCheck check weigher can be send to the label printer. 13. Automatic box labelling. 14. Ice dispenser. 15. Automatic strapping 16. Robot controlled palletising of the boxes.
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We also provide the scanners, printers, bar code readers and overall software solutions for entire plants. We provide modern processing plants featuring customised solutions that are both highly efficient and exceptionally user-friendly. Such customised installations can be built around specific customer requirements regarding monitoring and day-to-day production processes. 13
Major Benefits • Gentle product handling • High level of automation • Proven, reliable technology • Easy access for cleaning • Lower costs for: operators cleaning maintenance • Optimised operations • Full traceability • Rapid, accurate grading • Standardised modules • Improved flexibility • Scalable capacity • Integrated order management
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Intelligent batching of dried salted cod The Norwegian fish processor Andreas Bjørge AS had a problem: They needed processing equipment that could compensate for the varying water content in their salted dried cod. Grading and batching of fish is a standard operation. But when you have to be able to compensate for the loss of weight in a batch due to evaporation of water as it is transported from Norway to customers in Southern Europe it is a different matter. Owner Erling Bjørge explains, “We mainly export our products to Spain and Italy and the challenge was finding equipment capable of ensuring that our batches are not underweight when they arrive at the destination. But at the same time we do not wish to operate with a high giveaway.” The technical staff also had some specific
demands for the machinery because of the harsh, salty environment at the plant.
compensates for the varying water content in each individual batch.
Optical spectroscopy and high precision batching
“We are very pleased with the solution so far. After a running-in period we are now ready for our peak season over the summer where we expect to see improvement in yield as well as a reduced giveaway,” Erling Bjørge concludes.
The right solution to the problem was Scanvaegt’s high precision ScanBatcher 4700 weighing machine paired with the unique QMonitor technology. Based on near infrared spectroscopy QMonitor can determine characteristics such as color, fat, water and pigment content in fish fillets based on light reflection and transreflection. The results of this analysis are sent to the ScanBatcher which then
Water compensation is possible with the Q-monitor near infrared spectroscopy
Service is a collaborative partnership
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In a recent survey on what is most important to food processing operators the two top scorers were product reliability and after sales service. This is why Marel Food Systems have a sharp focus on providing global services. Food processors worldwide face numerous challenges because of changing consumer behavior, intense competition and issues such as traceability and health risks. The need for service availability and support worldwide is therefore on the increase.
AEW Delford, Carnitech, Marel and Scanvaegt are dedicated to providing the best-in-class service for our customers.
says Mr. Henrik Ladefoged, Service Director at Scanvaegt International.
flexibility in putting together a customer service and support package tailored to your exact requirements.
Unparalleled service organization Ensure maximum uptime More than 75% of all unscheduled interruptions to food processing operations can be directly attributed to human error in the form of lack of familiarity with the processing equipment, incorrect operation, poor maintenance and carelessness. “Our main objective is to support our customers’ business operations via services that add value by ensuring maximum uptime, availability and peak performance from each of the food processing solutions we provide,”
With more than 300 trained and certified field service engineers, directly employed in over 30 countries across six continents and more than 1000 on-site interactions with customers every day, we have a unique insight in different production environments and processes. We also have the practical know-how on how to tackle the demands and challenges our customers face.
Modular service structure Our service products are arranged in a modular structure that gives you maximum
All field service engineers and office personnel are supported by clearly defined processes that focus effort, speed up problem solving and ensure that our own management is always fully aware of its responsibility for meeting your expectations. That is why we can promise you to be your professional partner in staying competitive, profitable and preferred.
By-catch separation at high capacity For easy and efficient separation of small fish onboard North Atlantic shrimp trawlers The new generation of Carnitech’s by-catch separator is improved in a variety of ways. Twice as wide as traditional separators, it provides a significant capacity increase, and the construction of the machine sets the scene for greater flexibility of operation. Focus in the design of the machine has in the main been for easy maintenance and easy cleaning as well as improved user friendliness. An open construction makes for optimised production hygiene through quick access to critical areas. A semi-automatic tilting system makes adjustment of the angle of the conveyors less time consuming than before and greatly contributes to improved user friendliness as well as a high level of accuracy in the separation process. The unit has a longer service life owing to the fact that the plastic sprocket has been replaced by a robber roll. Consequently customers can expect a reduction in wear-related damage.
AEW Delford Systems Pinetrees Road, Norwich NR7 9BB UK Tel: +44 (0) 1603 700755 Fax: +44 (0) 1603 700844 www.aewdelford.com
Carnitech A/S
Juelstrupparken 14 DK-9530 Støvring Denmark Tel: +45 99 86 40 00 Fax: +45 99 86 40 01 www.carnitech.com
Editorial staff
Dorthe Mohn Christensen Ásgerður Jóhannsdóttir Jesper Hjortshøj Tina M. Søndergaard
Photographs
AEW Delford, Carnitech, Marel and Scanvaegt
Design and graphic production Datagraf A/S
Marel hf.
Austurhraun 9 IS-210 Gardabaer Iceland Tel: +354-563 8000 Fax: +354-563 8001 www.marel.com
Scanvaegt International A/S P.O. Pedersens Vej 18 DK-8200 Aarhus N Denmark Tel: +45 89 30 44 44 Fax: +45 86 78 58 10 www.scanvaegt.com
Subject to change without notice / 95002.04.07.Int. Advantage-FISH
Marel Food Systems is a global leader in its field, employing over 2000 people in 22 countries.
