ULTIMATE, WHOLE LEG DEBONING
WITH SURGICAL PRECISION
The ULTIMATE at work
PRECISION AND EFFICIENCY AT ITS BEST
Integrated J-Cut Unit
This machine is a total game changer when it comes
to whole leg deboning technology. The ULTIMATE
measures each leg and makes precise cuts based on
the feedback it gets from the X-ray unit.
This specially designed unit makes a precise cut
along the bone without damaging the meat or the
bone; ensuring reduction of pressure during meat
stripping, simplifying inspection and allowing for
good presentation.
That’s right, the guessing game is OVER!
Exceptional yields.
No bones about it.
FOODMATE ULTIMATE END RESULTS
Fieldale Farms is a family business, still owned by its
founders, but has grown to become one of the larg-
est independent poultry producers in the world. The
Murrayville plant operates two shifts and produces
around 1 million pounds of boneless leg meat per
week for its customer Chipotle.
CUSTOMER
Fieldale Farms
FOODMATE EQUIPMENT
ULTIMATE
SCOPE
Equipment Testing
“We want to thank Fieldale for their
trust and support and the business
they have awarded us.”
PAGE
10
SCOTT HAZENBROEK
Last year during IPPE 2017, Foodmate and Fieldale
started conversations about their plans to expand
the leg deboning operation and how it is becoming
increasingly difficult to meet their weekly production
goals due to the tight labor market. Therefore, as part
of Fieldale’s expansion plans to help overcome labor
issues was to find new technology and suitable auto-
mation to help improve yields.
“Last year during IPPE 2017, Foodmate owner, Scott
Hazenbroek showed us a video of the prototype whole
leg deboner they were working on and it showed a lot
of promise. We told Scott if Foodmate had the need of
a test location, we would be happy to work with Food-
mate and offered the Murrayville plant as a testing fa-
cility.” - said David Rackley, Plant Manager, Murrayville
Complex.
Based on that invitation, Foodmate installed the
ULTIMATE Whole Leg Deboner in November 2017 and
started testing and fine tuning the machine. After two
weeks of getting the machine dialed in, Fieldale start-
ed running the machine in full production during two
shifts and 5 to 6 days a week.
“Bringing the machine into a test location where
they actually run four leg deboning lines was a great
opportunity for us to compare our results against
Fieldale’s current process and to learn more about
the ULTIMATE’s performance and technical aspects.
In addition, we were able to get great feedback from
David and his team so that we could incorporate any
potential design changes they suggested.” - said Scott
Hazenbroek.
For a new and unproven machine in a US production
facility, the installation has gone well with no substan-
tial technical issues that have presented itself since
the machine has been running.
Fieldale’s main goal for the new equipment is to
reduce labor and improve yields and after running the
machine since November, Fieldale is very confident
that the machine is a big improvement over their cur-
rent process and it will help them with their challenges.
This success has led to the decision of purchasing the
machine used in the testing as well as 3 additional
machines, all to be installed once Fieldale’s planned
building expansion is completed in August.
“It was a very easy decision to make, the equipment
appears to be extremely reliable and despite the fact
that it uses cutting edge technology such as the X-Ray
Measuring System, it is a simple machine to operate
and maintain. The most important thing is to keep the
blades sharp. We attribute the consistent results and
high yields to the X-Ray Measuring System. Previous
technology always required to find the best middle
of the road setting, was labor intensive and required
skilled people to operate. The ULTIMATE measures
each leg and makes precise cuts based on the feed-
back it gets from the X-ray unit. This machine is a total
game changer when it comes to whole leg deboning
technology. Scrape tests are showing an average im-
provement of 33 grams per whole leg compared to
our current process and we fully expect to have staff
headcount reduction by 100 once the new machines
are installed.” - stated David Rackley.
Foodmate’s relationship with Fieldale started when
the Cornelia plant started looking at thigh debon-
ing solutions. This was the beginning of what has
become a fruitful relationship for both companies. The
success of t he thigh deboners has led to the order of 3
OPTI Flow Cut-up Systems, and now, the purchase of
4 ULTIMATE Whole Leg Deboning Systems.
X-Ray Measuring System
Precise measurements for precise cuts
The ULTIMATE uses the latest X-ray technology to precisely measure each
whole leg, allowing the machine to cut with accuracy around the knee joint,
User-friendly touch-screen
gives real-time production
information.
leaving the kneecap attached to the bone and ensuring very high yields and
minimal labor during trimming.