SUCCESS STORY
WHAT OUR CUSTOMERS ARE SAYING
FM STRATEGY
From conception to execution, Foodmate used a team approach in close
collaboration with the customer. Due to the size of the project, there were
multiple integrators involved so it was very important to remain flexible
in all stages of the project. This was a major investment for Gerber’s with
a lot of new technology and several partners/integrators, so Foodmate
CUSTOMER
Engineering, Projects, and Service teams all worked collaboratively to
Gerber Poultry · Kidron, Ohio
minimize any potential gaps.
FOODMATE EQUIPMENT RESULTS
Poultry grading, distribution and OPTI Flow Cut-up System drip line out Gerber Poultry reported that all objectives and goals have been met.
of the chiller to a weight transfer system to distribution line with vision Especially the improvement in product flow and reduction in double
grading. Three (3) buffer transfer machines to three (3) retail f rame cut up handling. Gerber’s management is very pleased with the entire project
lines, multiple WOG drops and one 8/9 piece cut up line. and would recommend Foodmate US to others in the industry. To allow
for minimum downtime the project was installed during multiple phases
SCOPE
The scope of the project was to provide grading and cut-up for 220 birds
per min out of the chiller. From the chiller, the birds are introduced to
a distribution line where the birds are weighed and graded and then
distributed to the appropriate WOG drops or cut up lines based on weight
and grade.
the system is functioning as promised and the investment is meeting all
expectations.
PRODUCTION AND
DISTRIBUTION SOLUTIONS
When we asked how was the interaction with Foodmate team members
throughout the project, Gerber Poultry reported that communication and
interaction were good before, during and after install. “The entire project
POULTRY GRADING FOR THE 21ST CENTURY
was very smooth. It started up with no downtime” stated Matt Shoup,
OBJECTIVE
The main goal was to increase production, improve product flow through
the plant, reduce labor; increase A grade pack out and reduce double
handling.
and the project has evolved during each phase. But the end result is that
VISION AND GRADING
General Manager. “We chose Foodmate largely because of the type of
company Foodmate US is - not so large that the customer doesn’t know
who to call, with a flat organization, flexibility, and ability to respond to all
service and parts needs immediately”, added Matt.
Has Gerber Poultry noticed any improvement since installation?
The plant eliminated 2nd shift Choice
Department
which was 9
employees – now on 2nd we run with 1 department 33 employees. Savings
of around $243,360 but if you add back the 4 people on 1st
shift to do
wings we actually cut 5 positions $135,200 to bottom line. “As a company
we are running more lines and have basically the same staff ing and
putting more lbs through.“We almost doubled our production now
through the cut-up lines. You have to consider the waiver also going f rom
140 to 175 has helped. This has made a difference with having product to
run through the machines with 140 bpm, we were struggling to run them
all before.” stated Becky Rhodes, Vice President Production/Operations.
THE STRENGTH OF FOODMATE & CHICKSORT
PRODUCTION AND DISTRIBUTION CONTROL SOLUTIONS
Foodmate and ChickSort are introducing a whole new generation of ChickSort Production
Control, Grading and Distribution Solutions. ChickSort 3.0 is the most advanced user friendly,
INVISION DETECTION PARAMETERS:
graphics based grading and distribution software on the market today with seamless
integration to Foodmate OPTI FLOW Cut-up Systems.
ChickSort 3.0 allows processors
achieve a high level of control and information without having to buy a complete new 9 9 Skin flaws/barking 9 9 Hock burn
packing room. Systems can be integrated with any existing line equipment . 9 9 Single leg hang 9 9 Bile stain
Utilizing a simple graphics based user interface ChickSort3.0 ensures that production control 9 9 Physical size 9 9 Bruises
is placed firmly back in the hands of the user. ChickSort3.0 ensures that every part of every 9 9 Broken wings 9 9 Feathers
bird is accounted for. Utilizing an advanced dashboard to display real time process status, 9 9 Missing parts 9 9 Organs
9 9 Hock length 9 9 Missing shackle detection
management can see at a glance what is being produced where. By splitting process control
into three distinct areas: whole bird; front half; and back half, ChickSort3.0 permits maximum
process flexibility. New users will benefit greatly from ChickSort 3.0 ‘s advanced process
From the left: David Coburn (National Account Manager,
Foodmate) and Mike Gerber (Owner of Gerber Poultry).
“Our production is much more streamlined, no
WOGS are kept in inventory, no double handling, the
Invision Camera Grading System has helped with
getting more A-grade WOG selection and ultimately,
fill customer orders. Without having to keep WOGs
in inventory, yield and shelf life are immediately
improved. The system layout was key in optimizing
this product flow.”
control capabilities.
CHICKSORT 3.0 OPERATING SYSTEM
Matt Shoup, General Manager
Gerber Poultry · Kidron, Ohio
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The advanced Dashboard 9 9
indicates at a glance: 9 9
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CHICKSORT 3.0 DASHBOARD
FOODMATE CUT-UP SYSTEMS
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THE LINES JUST RUN!
Current production
Combined piece rate
Total piece production
Individual line histogram
Total production histogram
Grade performance graph
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Average bird weight
Whole bird weight spread
Individual line speeds
Hanging efficiency
Reference position
Hanging efficiency per line
and combined
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