Beefing it Up

Sigpack Systems and CFS Join Forces to Create the Ideal Meat Processing and Packaging Line.

Following an increase in the number and intensity of industry regulations, the meat processing industry has been under unprecedented pressure to up the hygiene standards of its production and packaging facilities. To help meat producers deal with these new challenges and maximise efficiency, two of the most respected leaders in the processing and packaging industries have joined forces to merge corporate competencies. CFS, specialists in meat processing and packaging, have called upon Bosch Packaging Technology, leaders in packaging robotics and automation, to develop the next generation of meat processing lines. As part of the partnership, the two companies have devised a fully automated technology that has revolutionised meat packaging.

Roland Czuday, Product Manager, Delta Robot Systems at Sigpack Systems, a Bosch Packaging Technology Company, and Joachim Hajek, Product Manager, CFS RobotLoader at CFS, speak about the challenges the industry currently faces, and the solutions this unique team effort can provide.

What was the reason behind the collaboration between Sigpack Systems and CFS?

Hajek: As a company specialising in the processing, slicing and packaging of protein-based foods, CFS are constantly trying to improve product quality for the consumer and productivity for the manufacturer. While we have always been at the cutting edge of hygienic packaging in this industry, we also needed advanced robotic technology to make our idea a reality. Sigpack Systems, with their experience and advanced technologies in robotics and automation, were the obvious choice of partner to achieve this objective.

Czuday: We recognized immediately that this collaboration could revolutionise the meat packaging process. To increase hygiene as well as productivity, we sought to create a fully automated, customised solution that would eliminate a key problem in protein-based production - human contamination - while realizing tangible productivity benefits. Pairing CFS’s knowledge and experience of meat industry hygiene requirements with Sigpack Systems’ robotics know-how and tailor-made technologies allowed us to provide a solution we could not deliver separately.

What are the most significant challenges within the processing and packaging of protein-based products?

Hajek: Due to a recent tightening in regulations as well as increasingly quality-sensitive consumers, the meat processing industry has been faced with higher demands for hygienic packaging. Meat processors, like all food manufacturers, must deliver safe products or risk their entire reputations. As humans are the main risk factor for food contamination, we knew we needed an alternative to the manual loading of thermoformers and traysealers in packaging lines, which is the current norm in the industry. Added to this, unpleasant working conditions are common in the processing of protein-based products, which are further exacerbated when dealing with frozen and refrigerated products.

Czuday: Meat processors must not only provide top product quality but are also faced with the need to increase productivity and output. There is also a greater need for flexibility due to demand for changing product varieties and formats, which must be met with as little downtime as possible. In addition to actual production, cleaning and maintenance are also critical, and can greatly affect Overall Equipment Effectiveness (OEE). Machines need to be designed to be cleaned quickly and easily while still providing high quality and a safe production environment

How does the alliance between Sigpack Systems and CFS help businesses to tackle these challenges?

Hajek: Through the alliance, we developed a customized production line specifically designed to meet the unique demands of the meat industry – a flexible packaging system able to ensure high quality whilst minimising human contact with machinery and product. The system includes customized Delta Robots from Sigpack Systems that enable manufacturers to adhere to the strictest hygiene standards and increase productivity.

Czuday: Thanks to the fully automated robotic solution capable of performing in even the most difficult environments, producers will be able to bypass the human contamination risk posed by the hand-loading of trays. The very design and materials of the robots greatly contribute to plant hygiene. Standard robots used in food processing are equipped with protective covers that can have crevices and hollows that are difficult to access and clean. The Delta Robot avoids this problem with minimal housing and specially insulated electronics. Its streamlined, stainless steel design prevents the accumulation of germs and allows for easy access. As the first complete wash down robot, the Sigpack Systems Delta Robot withstands even aggressive cleaning agents and can be washed down in half the time needed to clean a conventional robot. This not only helps businesses to increase uptime but also requires less manpower for cleaning than traditional robots, thus freeing up operators for other tasks. The hygienic design is not just limited to the robots, but extends to all components of the robot loading cell, including image capture, vacuum system and grippers. Thus, manufacturers can rely on overall hygiene in the production environment.

Hajek: With the fully automated robot cells, our production lines also greatly improve the convenience and ease of use for line operators and staff for improved work conditions. Each robot has a dedicated vision camera to identify location and orientation of the products it is handling, which reduces the need for human supervision whilst increasing reliability and speed. Manufacturers also have the potential to significantly increase output potential as our Delta Robots are the fastest robots available, capable of handling 800 products or 250 packs per minute. The new technology gives businesses the flexibility needed to handle different arrangements and presentations in the pack to best meet consumer demands. The system allows operators to execute a complete format changeover in only ten minutes.

How will meat producers benefit from the Sigpack Systems/CFS collaboration?

Hajek: Basically, due to our collaboration, the meat industry now has access to the most reliable and hygienic automated packaging solution currently possible. As brand trust is of particular importance right now, the high product quality our line ensures is an asset to meat producers. The flexible equipment has the potential to significantly increase OEE, and can be easily incorporated into existing lines, thus minimising the need for businesses to replace whole systems. In addition, workers will benefit from improved working conditions and easier cleaning and maintenance as well as easier and more reliable operation through the automated design. The collaboration has resulted in a highly efficient and hygienic solution for manufacturers.

Czuday: Thanks to the one-stop-shop nature of our new line, producers are able to rely on only one supplier for all packaging needs. This cuts lead times and saves manufacturers the need to coordinate between third parties. Instead, they are guided by our dedicated, coordinated consultancy and have access to a team of experts to solve individual needs and challenges. They will also have access to an after-sales support programme set up to extended machine lifetime through dedicated servicing. This is the only currently available solution allowing meat producers to work with one supplier providing robots as well as meat processing and packaging machines.