Cutting cubes from chicken fillets adds a lot of value to your products. The cubes are the basis for various meals all around the world. It is essential to control the weight and shape of the cubes when producing fixed-weight packs for retail or food service. In order to be profitable, cubes must be cut at high volumes with minimum labor and maximum efficiency.
The development of the strip separator was the right step for MARELEC due to the increasing worldwide demand for cutting cubes. Cutting cubes with a MARELEC cube cutting line first involves a portion cutter that cuts strips from a fillet.
The strips are then singluated and alligned by the Strip Separator. Operators check for default and perform a quality check.
In third stage, the second portion cutter cuts fixed-weight cubes. The strip separator enhances the efficiency of the entire line. It reduces labor reduction and increases of throughput. Furthermore, it increases yield with a better-looking end-product because the strips are almost perfectly aligned. This alone makes it a worthy investment.
The first dual-lane PORTIO DAP will scan and cut the fillets into strips on both lanes. The intelligence of the first portion cutter ensures that the front and back trims are kept to a minimum. Depending on the size and shape of the raw material, the portion cutter will calculate where to make cuts to create the best-looking strips. Flattening the chicken fillets prior to cutting the strips will help to create a better looking strip. One benefit is that it increases the efficiency of the strip separator which means less work for the operators.
The second PORTIO 1DAP is placed at 90° so the individual strips have the right orientation and cuts the strips into fixed-weight cubes. This portion cutter also uses its intelligence to cut at the highest yield possible.
With a constant and efficient infeed of the fillets, you will be surprised by how many ton per hour you can produce.
The PORTIO software for the Portion Cutter always calculates the cuts so as to leave zero waste, and maximize the yields. Conditional programs are possible for in increased yields. Since this uses two portion cutters, we can already optimize the yield by cutting the right sized strips to make sure you have the right strip for the right cube. This is done by intelligently programming the first step which will result in an optimized and thus higher yield.
Strip separation is a very intensive operation, because of that the speed the strips arrive at the second portion cutter. For this reason, the number of operators is reduced from 6 to 2 operators at the infeed of the second PORTIO. These 2 operators only need to perform a corrective operation which enhanse the ergonomics of the whole lane.
Using the strip separator to cut cubes is the most cost-effective solution. It requires a low investment, has a high capacity and compared to other solutions the maintenance costs are extremely low. In addition, it keeps the footprint to a minimum.
The strip separator and portion cutters are extremely quiet which creates a comfortable environment for the operators to work.
The strip separator is a very straight forward solution. Because of its experience MARELEC was able to design this simple solution, which needs no complicated setup or machines. By using a intelligent driven belt system the strips are separated and fed to the second portion cutter.