Success Story

Koch Foods

The goal for this plant was to replace hand-thigh deboning lines to achieve a higher production level while maintaining yields and reducing labor costs.
Foodmate Equipment

(3) OPTiX Thigh Deboners
(2) OPTI Flow Cut-up Systems
(2) Leg Processors

Scope

Foodmate has replaced the plant’s hand thigh deboning lines with 3 OPTiX Thigh Deboners. The main goal was to deliver labor reduction and meet or exceed yields. For this to happen, our team’s goal was to provide a solution that improved the thigh deboning process’ performance and increased the number of thighs with the oyster attached.    

FOODMATE STRATEGY

Our team analyzed the plant’s needs and developed a solution that addressed the main goal: maintain or increase yield and decrease labor. To that end, our engineering team provided a plan to include three OPTiX Thigh Deboners, two OPTI Flow Cut-up systems, which included replacement of the chain, shackles, and leg processors of their existing line to send an anatomical cut whole leg to the OPTiX.

Our team’s target was to deliver our equipment on schedule and ensure a smooth start-up with minimum downtime.

Solution & Results

The ideal solution was to install 3 OPTiX along with the OPTI Flow Cut-up lines for optimal yields while at the same time reducing staffing. The project has been a success.

How did we do?

Follow up interview with Ed Fletcher, Complex Manager and John Waggoner, Plant Manager

We had a few tests at the Foodmate Demo and Training Center, which proved the machine’s high performance. The small amount of bone and cartilage on the meat that comes off that machine impressed us. The OPTiX maintains a constant high yield. Also, we were confident with the support Foodmate provides.

We had a few tests at the Foodmate Demo and Training Center, which proved the machine’s high performance. The small amount of bone and cartilage on the meat that comes off that machine impressed us. The OPTiX maintains a constant high yield. Also, we were confident with the support Foodmate provides.

Overall, the OPTiX has done a great job, it allowed us to cut back on overtime on weeknights and weekends, so we improved workflow. It helped us to improve in re-work, and we were able to streamline production. This has been a very successful project. We show labor improvement to be very close to what we anticipated; we estimate our crew reduction at about 60 people. Labor cost has gone down, and we have stabilized our labor force.

I think our team has done well with the machines. They took ownership of the new equipment and have adjusted well, learning the new equipment quickly. It helps that these machines are relatively simple to operate and maintain. We feel that the training provided by Foodmate was very supportive of the adaptation process as well.

The Foodmate team did a great job on both day and night shifts; they were knowledgeable and easy to talk to; they got our team involved, training them, helping them to get comfortable with the equipment. Your install team did an excellent job!

Overall, the OPTiX has done a great job, it allowed us to cut back on overtime on weeknights and weekends, so we improved workflow. It helped us to improve in re-work, and we were able to streamline production. This has been a very successful project. We show labor improvement to be very close to what we anticipated; we estimate our crew reduction at about 60 people. Labor cost has gone down, and we have stabilized our labor force.

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