Basics of Meat Science by yurtgc548

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									    Useful Tools
For Meat Processing



      American Association of Meat Processors

                  One Meating Place
              Elizabethtown, PA 17022
      Phone: (717) 367-1168 Fax: (717) 367-9096

              Website: www.aamp.com
              Email: aamp@aamp.com
                 Clipping Machines

•   Clipping method progression
    •   Hand tying
    •   Hand clipper
    •   Pneumatic clipper
    •   Automated clipper
                     Clipping Machines

•   Overview
    •   Understand the investment costs
         •   Cost of machine
         •   Cost of clips
         •   Cost of casings
         •   Cost of what you are currently using
         •   Cost of your time
    •   Cost of clips are twice the cost of other clips
    •   Sheared casings are twice the cost of other casings
                     Clipping Machines

•   Summer sausage
    •   Machine will go as fast as you want it to, but other
        production personnel may not be able to keep up

    •   Previous system (individual casings and clipper)
         •   2” casing and 400 lbs. load = 2 hours
         •   200 lbs. per hour

    •   Current system (sheared casings and automated
        clipper)
         •   2” casing and 400 lbs. load = 45-60 minutes
         •   400-450 lbs. per hour
                     Clipping Machines

•   Ring bologna
    •   Pound for pound of product produced, the collagen
        casing cost was the same as the natural casings

    •   Previous system (natural casings and hand tying)
         •   300 lbs. per smokehouse truck = 1 ½ hours to stuff/tie/hang
         •   200 lbs. per hour

    •   Current system (natural casings and automated
        clipper)
         •   300 lbs. per smokehouse truck = 20 minutes to stuff/clip/hang
         •   900 lbs. per hour
                      Clipping Machines

•   Braunschweiger
    •   Hidden benefit is the fact that the machine allows for
        much cleaner production with the braunschweiger
        batter

    •   Previous system (individual casings and clipper)
         •   100 lbs. product = 30 minutes to stuff/tie/hang
         •   200 lbs. per hour

    •   Current system (sheared casings and automated
        clipper)
         •   100 lbs. product = 6-7 minutes to stuff/clip/hang
         •   825 lbs. per hour
                     Clipping Machines

•   Take home message
    •   Time saver
         •   Sooner you get done with one task the quicker you can get to
             the other tasks
    •   Physical labor saver
    •   Stagger production to maximize the usage of capital
        equipment investment
    •   All the benefits gained justified the investment of
        money to make more money
Automatic Clipping Technology
    Automatic Linking & Hanging System

•   Stuffing method progression
    •   Straight stuffing & hand hanging
    •   Link stuffing & hand hanging
    •   Automated stuffing & automated
        hanging

•   Cost benefit may not solely be due to
    increased production, but also
    attributed to product consistency
    Automatic Linking & Hanging System

•   Straight stuffing & hand hanging
    •   Production
         •   2,400 lbs. / day (300 lbs. / hour)
         •   Problems
              •   Casing and stuffing was highly variable
              •   High volume of rework produced

    •   Final product
         •   Label = 1.5 ounces
         •   Actual package = 1.7 ounces to
             account for product variability
    Automatic Linking & Hanging System

•   Automated stuffing & automated hanging
    •   Production
         •   6,400 lbs. / day (800 lbs. / hour)

    •   Final product
         •   Label = 1.5 ounces
         •   Actual package = 1.5 – 1.6 ounces
         •   Increased production by 6 cases / 800
             lbs. of sausage batter or 6 cases / hour
    Automatic Linking & Hanging System

•   Take home message
    •   Removed stuffing operator variability
    •   Increased production by 6 cases per hour =
        $2,500/day
    •   Decreased risk of customer complaints and USDA
        label misbranding due to potential under-weight
        packages
    •   Operates at 70-75% stuffer speed
         •   Speed is essentially based on how fast the operator can load
             the sheared casing on the stuffing horn
         •   Easier on the equipment
Automatic Linking & Hanging System
                       Packaging

•   Packaging method progression
    •   Butcher paper
    •   Shrink wrap / Over wrap
    •   Vacuum bags
    •   Rollstock
                        Packaging

•   Machines are designed to run very similar
    size/consistent products to be the most efficient
•   Costs are highly variable
    •   Dependent on what a processors is packaging
    •   The number of cycles (dependent of the size of the
        product)
    •   The index length (dependent of the size of the product)

•   Traditional vacuum bags are approximately twice the
    cost of rollstock
                             Packaging

•   Processor experience
    •   Achieved 1966 cycles -
         •   2 rolls forming film (7 mil) & 1 roll cover film (2.5 mil)
    •   Cost
         •   1 cycle = $0.32 per package
         •   1 x 1 per cycle – 2 packages = $0.16 per package
         •   1 x 3 per cycle – 3 packages = $0.08 per package
         •   2 x 2 per cycle – 4 packages = $0.11 per package
         •   2 x 3 per cycle – 6 packages = $0.05 per package
                              Packaging

•   Take home message
    •   Savings
         •   Packaging supplies
         •   Labor (less employees needed)
         •   Time (gets the packaging completed quicker)
         •   Increased final product quality
              •   Decreased broken packages – if it hasn’t sealed correctly
                  it will typically be recognized at the establishment before
                  it is shipped
    •   Consider purchasing bigger/longer machines due to
        other added features (labeler, hole puncher, cross-cut
        knives, etc.)
              Vacuum Shrink Bags

•   High shrink in hot water tunnels
•   Oxygen and moisture barrier properties to maximize
    shelf life
•   High gloss, low haze to enhance appearance
•   Available in a range of factory shapes and sizes
             Hot Water Shrink Tank

•   Shrink vacuum bags uniformly
•   Adjustable dipping cycle time
•   Creates an attractive final packaged product
•   Final packaged product appears more
    “eco-friendly”

•   Cost: $8,000
                       Brine Mixer

•   Dissolves ingredients more thoroughly
    •   Phosphates, soy protein, etc.
•   Dissolves ingredients more consistently
•   Speed controlled
                   CO2 Chilling Unit

•   Maintains and/or decreases
    temperature of the raw
    materials quickly
•   Good for pre-rigor
    processed meat products
•   Fitted on existing equipment

•   Cost: $1,200
Questions

								
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