PARTNERSHIP APPROACH SUPPORTS POULTRY PROCESSOR’S GROWTH
As a result, the Taravis factory is today able to handle 8,000 birds per hour, 64,000 in a day, compared to the 14,000 birds per day that it handled when it first opened in 2001. Equally significant, efficiencies have hugely improved. Whereas previously slaughter of the birds would take place during one shift, while the next two were then devoted to packing, now both processes are undertaken in a single shift as part of an inline operation. Just as significant, product giveaway has been greatly reduced. In recent years, it is now less than 3% across s the entire factory whereas previously it was well over 6%, or as managing director Ákos Szabó puts it “far too much” pointing out that this figure does not take into account the yield loss through the trimming of birds to meet the required target weight. Key to the higher speed and accuracy in the packing process has been the replacement of the slow and labour-intensive hand packing operation with two Ishida Flex Graders, one Robotgrader and two multihead weighers, which ensure consistently accurate weights for the pre-packed trays and vacuum packs of chicken. In particular, the Robotgrader, which combines weighing and pick and place technologies to grade chicken pieces and pack them to a fixed weight straight into the tray, is able to minimise giveaway to less than 1%. To handle these higher speeds for the packing of product into trays, Ishida designed an effective distribution system to transfer the chicken pieces to four Ishida QX traysealers, whose top speeds are well within the 60 trays per minute target for Taravis. In addition, the introduction of the Ishida traysealers enabled Taravis to become the first poultry processor in Hungary to introduce top sealed MAP trays into the retail sector, offering extended shelf-life and enhanced presentation compared to the previous shrink-wrapped version. Today the factory is producing around 25,000 MAP trays each day. Ákos Szabó confirms that Ishida’s expertise and experience have been crucial to the company’s growth and development. “Ishida has always been able to fully understand our requirements and come up with the appropriate approach to support our drive for continuous improvement,” he explains. “At the same time, the installation of a new machine can present challenges elsewhere on the line in terms of maintaining throughput and avoiding bottlenecks, or simply in terms of ensuring it can fit into the existing layout. This is where the benefit of working with Ishida is very evident as the company is always able to come up with solutions to help us achieve our objectives with minimum fuss.” In addition, Ishida provides full training on any new equipment installed. Another major benefit of the Ishida equipment is its reliability. “Indeed, our satisfaction with the performance and reliability of our initial Ishida equipment is another reason why we have continued to specify Ishida machines throughout the factory,” says Mr Szabó.