Marel simplifies primal cutting with vertical precision
By integrating vision-based cutting and ergonomic design, DeboFlex simplifies operations and delivers consistent, high-quality results.
marel.com
Ever wondered if vertically performing primal cuts could streamline your process, improve yields, and reduce labor reliance? While traditional methods have been widely adopted and work effectively for many processors, there’s always room to explore opportunities for improvement. What if you could optimize this critical step in pork processing to achieve even better results?
Rethinking the primal cut process
In many meat processing facilities, primal cuts are traditionally performed horizontally. While this approach has served the industry well, processors are now exploring innovative alternatives to address challenges like labor dependency, consistency in cutting accuracy, and operational efficiency.
Vertical primal cutting is emerging as a valuable option for achieving greater precision and consistency. By aligning carcasses and automating key steps, this method offers the potential to enhance yield, reduce waste, and improve overall process flow—all while requiring less manual handling.
Introducing the DeboFlex approach
The DeboFlex Primal Cut system offers an inline, modular solution that prioritizes accuracy, efficiency, and flexibility. By integrating vision-based cutting and ergonomic design, DeboFlex simplifies operations and delivers consistent, high-quality results.
Key advantages of vertical cutting with DeboFlex:
- Improved Cutting Precision: Vision-based technology ensures consistent cuts.
- Enhanced Ergonomics: Operators benefit from better visibility and optimal working positions, minimizing strain during tasks like tenderloin removal or flank opening.
- Increased Safety: Stand-alone cutting modules create a safer environment for operators when comparing to conventional primal cut tables.
Flexibility meets efficiency
The modular nature of DeboFlex allows for tailored solutions depending on the specific needs of a processing plant. For example:
- Operators can perform anatomic shoulder cuts for a variety of production specifications.
- Logistics are streamlined with an overhead transport system that positions carcasses for optimal processing.
- High-yield tasks, like tenderloin or tailbone removal, can be executed with improved ergonomics.
- Adjusting primal cut height position during production depending on product specification, e.g. hind-leg/middle splitting position from 1.5 inch straight vertebra (EU specification) to 1 inch from the aitchbone (US specification)
This flexibility ensures that processors can adapt to changing requirements while maintaining consistent performance.
Angled cutting: An added advantage
Another benefit of the DeboFlex system is its ability to incorporate angled cuts where necessary. By adjusting the cutting angles for specific carcass sections, the system enhances yield and reduces waste. This level of precision ensures better utilization of high-value meat sections, contributing to improved overall efficiency in the cutting process.
Proven results in real-world applications
DeboFlex has already demonstrated its value across the globe, with more than 5 million pigs processed to date. By transitioning to vertical primal cutting, processors have seen:
- Increased Yields: Cleaner, more accurate cuts maximize the value of each carcass.
- Reduced Waste: Precision cutting minimizes damage to valuable sections like the belly and ribs.
- Optimized Operations: Processing up to 900 pigs per hour, the system ensures high throughput without sacrificing quality.
The bigger picture: efficiency and sustainability
Beyond operational benefits, the DeboFlex system supports a more sustainable approach to meat processing. By optimizing product value and minimizing waste, it helps processors meet industry expectations for efficiency and environmental responsibility.
Switching to vertical primal cutting isn’t about replacing tradition—it’s about exploring new ways to improve. Vertical cutting offers processors the opportunity to deliver consistent quality, reduce costs, and create safer working conditions for their teams.
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