Maximizing quality and minimizing costs
with fully automated production lines
All machines and systems from a
single source
By using a single supplier, like GEA,
all machines, programs and interface
are standardized, so that all process
information can be shown inside the
entire system for all equipment. The
advantage is that data are aligned and
comparable, visible in one system and
standardized over one level. When
a producer uses different systems,
they must define all the integration
requirements that must take place. This
makes coming up with the offer, as well
as the installation and commissioning
phases much more complex. The reaction
time is much longer, given the number
of interfaces and various skills required.
With GEA, alignment with a third-party
Under the motto ‘Excellence at Every
Stage’, GEA presented its equipment and
solutions for diverse applications at this
year’s IFFA, key trade fair in the area
meat processing (May 2019, Frankfurt/
Germany). Key processing and packaging
exhibits demonstrated the benefits of
automation; optimal process control; as
well as the efficient use of resources,
Connecting modern machines
and ensuring effective running
Coupling meat treatment machines with
additional processing steps brings many
advantages to the overall production
process. The chicken nugget line from
GEA enables fully automatic production
via batch execution based on a process
energy and labor in meat manufacturing. recipe. A major advantage of having a
The technology company is recognized recipe must only be read once, sending
worldwide as a leading supplier of the parameters to the individual
complete preparation line solutions machines which then communicate with
for processed meat and poultry as each other. This automatically triggers
well as other products. The production the pre-production phase, with materials
line for chicken nuggets, part of which
was displayed during IFFA, integrates
several machines responsible for recipe-
controlled meat grinding, mixing, forming,
coating, cooking, frying and freezing in
one seamless, fully automatic process
– proving that automation is more than
the robotization of single machines.
GEA offers a complete data-connected
production line that ensures consistent
high-quality products while minimizing
labor costs and with full traceability.
54 FDPP - www.fdpp.co.uk
centralized system is that the product
provided just-in-time from silos, which
means that much less labor is required
and human error is kept to a minimum.
Likewise, nugget quality is improved
since the components are supplied at
a constant temperature, mixture and
consistency. The extremely fine-tuned
system ensures low tolerances, so that
the degree of deviation is very low. After
production, reports are available to check
the process conditions of each batch.
interface is unnecessary as the company
provides the complete line from offering,
installation and commission from a single
hand.
High production capacity with
low labor costs
The chicken nugget line includes the GEA
MaxiFormer at its heart, which provides
very high production capacity, better
consistency and significantly lower
operating costs. The step-filling system
minimizes the pressure used to fill each
cavity carefully and progressively. This,
combined with its rigid drum design,
reduces wastage, improves filling
accuracy, creates a higher quality formed
product with excellent shape retention
and minimizes down time for cleaning.
Its knock-out system uses dry air at high
pressure applied only to the relevant
cavities, instead of the entire drum.
“This significantly reduces air usage and,
therefore, energy costs,” says Luuc van
Lankveld, GEA Product Expert. “That’s
an important innovation for achieving
economy in production.”