From managing varying produce quality to complying with stringent food safety regulations, protein manufacturers face unique challenges. These can include everything associated with the handling of irregular shaped, fresh products for weighing to the distribution of products with bone fragments and foreign particles which if undetected can result in complaints, fines, and recalls, potentially affecting the manufacturer’s reputation. Unfortunately, such issues can’t always be identified through human inspection.
Ishida offers a comprehensive range of solutions specifically to overcome such challenges. Read on to discover how their innovative products streamline and optimise protein production processes, improving efficiency, reducing waste, and increasing output for manufacturers.
Transformation of Protein Packaging
Driven by the unique Three Way Harmony philosophy, Ishida is committed to developing technologies that benefit customers, society, and manufacturers alike. This extends to the development of systems for enhanced precision and speed on the production line. Such systems are specifically designed to handle challenging products, such as sticky meats and irregular cuts, with greater precision than those of the competition.
For instance, Ishida’s computer combination weighers (CCWs) use highly precise weight distribution algorithms to deliver unparalleled accuracy and efficiency. Capable of processing up to 210 weighments per minute with an accuracy of just 0.5 -- 1.0 grams, the CCWs help minimise giveaway and maximise yield.
Protein manufacturers are also coming to realise the transformational impacts of Ishida’s IX-G2 X-ray detection system. Integrated with dual-sensor technology, this X-ray system can be relied on for the isolation of residual calcified bones and other low-density-foreign bodies. This reduces the risks of complaints, recalls, and damage to the reputation of customer’s brands.
Other benefits of Ishida’s production line technologies include:
- Industry-leading hygienic design, with easy-to-clean features reducing downtime and enhancing compliance with strict food safety standards
- Relatively fast changeovers and integration with automated systems, enabling consistent output even in high-demand environments
- Reduced reliance on manual handling and intervention, with associated staff expenses and risks also being minimised
- Flexibility and adaptability to different packaging styles, with the capacity to handle various tray and bag sizes and pack weights.
Examples of Success
Various food manufacturing companies have realised the benefits of Ishida’s production line technologies. For instance, Maple Leaf Foods reduced manual handling and improved poultry packaging efficiency at its state-of-the-art facility in Ontario, Canada. Ishida’s advanced sorting systems enabled throughput of up to 120 legs and 400 drumsticks per minute, meeting diverse needs with precision.
Recognising the demand for fixed-weight poultry packs, Saudi Arabia-based Almarai also took the opportunity to integrate Ishida’s food production line solutions. This partnership proved key to Almaraii’s growth, from the processing of 21,000 to 37,000 birds per hour at its poultry plant in Ha’il Province. The introduction of Ishida’s multihead weighers and X-ray inspection systems has significantly improved precision and hygiene with minimal giveaway.
The integration of Ishida’s X-ray solution has been key to the production of bone-free chicken breasts and thighs for the Norway-based Nortura too. More specifically, Ishida’s IX-G2 Dual Energy X-ray inspection systems have improved the detection of low-density contaminants that might otherwise have resulted in customer dissatisfaction and worse. Nortura is now able to identify fully calcified bones down to a size of 3mm or 4mm, with a fillet line belt speed of 25m per minute.
Revolutionising Protein Production with Ishida
Having made such a difference, it’s little wonder that Ishida’s innovative production line technologies have received great industry praise; winning in the innovative packaging machinery category at the Automate UK Awards. Ishida was also among the exhibitors at the 2024 PPMA show, with many visitors impressed by the precision, efficiency, and hygiene-enhancing benefits of its food inspection technologies.
From weighing machines to inspection and quality control systems, the entire range of innovative products can be viewed on the Ishida website. Manufacturers are encouraged to contact Ishida for consultation on the best means of transforming protein production lines with such cutting-edge solutions.