IE86362B1 - A system for deboning, trimming and packaging of beef - Google Patents

Abstract

Butchery products from a trimming line 90 are diverted to one of two quality assurance stations 70, 71 according to pre-determined protocol for inspection. At each station 70, 71, product identification and instructions are relayed to the operator via a terminal. A history of quality non-conformances is maintained and feedback provided. An intelligent flow line directs primals and trimmings to/from designated quality assurance stations 70, 71 so that the weight, identification and quality attributes of incoming primals/trims will be measured. This data will be continually fed to a central computer system which will give real time quality assurance data per primal/trim type and trimmer to the production supervisor(s). The first quality control station 70 is a static inspection station at which the trimmed cuts are inspected and feedback is provided via a terminal 73. After static inspection the meat cut may be re-introduced onto the main trimmed product conveyor 90. The second quality control station 71 comprises an inspection conveyor 72 to which meat cuts are led for inspection. Again, feedback and inputs are provided by a terminal 74. The output from the quality inspection station 71 may be directly packaged. <Figure 1>

Description

“A processing system” Introduction This invention relates to a system for deboning, trimming and packaging of beef.

Beef quarters (large portions of a carcass consisting of skeletal bones with beef tissue attached) are de-boned by skilled operators. These de-boned pieces of meat (called “primals”) are then subsequently trimmed by skilled operatives. Trimming involves removing extraneous fat, membrane and tissues which are not requested by customer specifications and are called “trimmings”. Primal cuts are then packaged for subsequent storage and distribution to customers.

One difficulty with known deboning and trimming systems is that numerous separate operations are required, all of which are labour intensive and some of which require highly skilled operatives. In conventional processing systems it is difficult to identify and correct any problems that arise at a particular workstation. This leads to major inefficiency with consequent added costs.

Statements of Invention According to the invention there is provided a meat processing system comprising:20 a meat cut delivery conveyor for delivery of meat cuts; an input weighing means for in-line weighing of meat cuts; a plurality of trimming stations; an output conveyor onto which meat, trimmings and fat from a meat cut are delivered; an output weighing means for in-line weighing of the meat, trimmings and fat associated with a trimmed meat cut; a first quality control station; means for diverting trimmed meat from the output conveyor to the first quality control station for inspection; feedback means to provide outputs from the first quality control station to a control system and/or to an operator at a trimming station; 2 86362 a directing means for directing the inspected trimmed meat from the first quality control station back onto the output conveyor; a second quality control station comprising an inspection conveyor along which meat cuts are led for inspection; and feedback means to provide outputs from the second quality control station to a control system and/or to an operator at a trimming station; and wherein the second quality control station is in series with the first quality control station and the output from the second quality control station is directly packed.

In one embodiment the first quality control station comprises a static inspection station.

In one case each meat trimming station comprises an input gate through which meat to be trimmed at the trimming station is delivered.

At least some of the trimming stations may be dedicated to particular primal meat cuts. All of the trimming stations may be dedicated to particular primal meat cuts.

In one case an input gate at a trimming station is opened in response to the approach of a primal cut associated with the trimming station. The system may comprise gate operating means for opening the gate in response to the approach of a primal cut associated with the trimming station.

In one embodiment each trimming station comprises an outlet for fat, and outlet for meat, and at least one outlet for trimmings.

There may be a first outlet for trimmings having a low content of visible meat and a second outlet for trimmings having a high content of visible meat. In one case the outlets are arranged side-by-side adjacent to an operator table.

In one embodiment each trimming station comprises a trimming interface means. The trimming interface means may comprise entry means for entering data relating to the cut trimmed at the station. The trimming interface means may provide directions to the operator at the trimming station.

In one embodiment the meat, trimmings and fat are delivered sequentially onto the trimmed output conveyor. There may be a control means for spacing apart the delivery of the meat, trimmings and fat from a primal so that gaps are provided on the trimmings output conveyor between the meat, trimmings and fat.

In one case the system comprises weighing means on the trimmed output conveyor for individually in-line weighing meat, trimmings and fat from a primal.

In one embodiment the trimming station comprises a bone outlet for removal of trimmed bones from the primal to a trimmed bone conveyor for delivery to a bone output conveyor. Each trimming station may include a bone outlet.

In one case the system comprises:15 a weighing station for weighing the fat trimmings; a scanner conveyor; first directing means for directing the fat, trimmings with low visible lean meat content and trimming with high visible lean meat trimmings from the output conveyor to the scanner conveyor; a scanner through which the fat, trimmings with low visible lean meat, and trimmings with high visible lean meat are led from the scanner conveyor to determine the fat content thereof: and second directing means to deliver the fat and trimmings from the scanner into a container dependent on the weight and fat content thereof.

In one embodiment the scanner comprises a tunnel through which the fat and trimmings are led along the scanner conveyor. The scanner may comprise an X-ray scanner or an infra red scanner.

In one case the system comprises third directing means for directing the meat cuts to a packaging station prior to delivery of the fat and trimmings through the scanner.

The system may include a primal meat processing system.

In one case the primal meat cut processing system comprises:a primal meat trimming, dividing and separating station to provide individual primal muscles; an output conveyor, onto which the individual primal muscles are delivered; an input weighing station for weighing the primal muscles; a membrane releasing station at which at least part of the membrane attached to the primal muscle is released / removed; a final trimming station for final removal of fat and/or membrane; and an output weighing station for weighing and recording individual membrane-removed primal muscles.

In one case there is a terminal at the output weighing station for inputting data relating to the individual membrane removed primal muscles.

In one embodiment the membrane releasing station comprises an automatically operated membrane releasing machine.

In another embodiment the membrane releasing station comprises a manually operated 30 membrane releasing machine.

There may be a packaging station downstream of the final weighing station. There may be a dicing station downstream of the final weighing station.

In one case the system comprises:a weighing station for weighing a cattle quarter; a plurality of primal cut removal stations; a plurality of deboning stations; an overhead track for moving a quarter between the stations, the track having a plurality of carriages, each carriage carrying a support hook for a carcass quarter; means for moving the carriages to advance the carriages sequentially along the track wherein the quarters are moved sequentially through each of the weighing, deboning, and primal cut removal stations; the carriages being movable simultaneously so that the cattle quarter has the same set residence time at each of the weighing, deboning, and primal cut removal stations.

In one embodiment the set residence time at each of the stations is from 20 seconds to 120 seconds. In one case the set residence time at each of the stations is from 30 to 60 seconds.

The system may comprise:a first primal cut removal station at which first meat cuts are removed from the quarter; and a first deboning station at which first bones are released and/or removed from the cattle quarter.

In one case the first deboning station is followed by a second primal cut removal station at which second meat cuts are removed from the quarter. In one embodiment the second primal cut removal station is followed by a second deboning station at which second bones are released/removed from the cattle quarter which is in turn followed by a third primal cut removal station at which third meat cuts are removed from the quarter.

In one case the system comprises:a cattle quarter loading station at which a carriage carrying a cattle quarter supporting hook is delivered onto the track in response to the completion of deboning of the last cattle quarter on the track. The loading station may comprise a hindquarter loading station and a separate forequarter loading station for alternate delivery of a cattle carcass hindquarter and a cattle carcass forequarter on the track.

In one case the system comprises scanning means at the weighing station for scanning a tag on a quarter.

Each primal cut removal station may comprise an interface means for inputting data relating to the cut removed at the station. The interface means may provide product identification & directions to the operator at the primal cut removal station.

In one embodiment the system comprises a meat output conveyor for receiving meat cuts removed at the primal cut removal stations. The meat output conveyor may be common to the primal cut removal stations.

In one case each meat removal station comprises an outlet gate or conveyor through which a meat cut is delivered onto the meat output conveyor. The system may comprise detection means for detecting a predetermined gap on the meat output conveyor and operating means for opening the outlet gate in response to detection of the gap on the meat output conveyor. There may be an in-line weighing means on the meat output conveyor.

In one case the system comprises bone output conveyors for receiving different categories of bones removed at the deboning stations. There may be a bone outlet hopper to which the bones are led by the bone output conveyor.

In one case the system comprises a transfer station for transferring a carcass from a chiller conveyor to an infeed conveyor system. The carcass may be suspended from the ischium on the chiller conveyor and the carcass is suspended by the Achilles tendon on the infeed conveyor system.

In one arrangement the infeed conveyor system comprises a forequarter rail and a hindquarter rail. The carcass may be initially suspended on the hindquarter rail and a lowermost portion of the carcass is divided from the carcass and hung on the forequarter rail.

In one case the quarters are delivered along the forequarter rail and the hindquarter rail to the main deboning overhead track. The system preferably comprises an indexing means for alternatively delivering a forequarter and a hindquarter onto the deboning overhead track.

In one case the system comprises recirculating means for recirculating empty carriages to the infeed conveyor system.

In one case the system comprises clearing means for clearing hooks prior to delivery of the hooks to the transfer station.

Also described is a cattle carcass processing system comprising a cattle carcass deboning system of the invention. In this case the system further comprises a plurality of meat trimming stations.

In one case the system comprises a meat output conveyor for delivery of meat to the trimming 20 stations. In one case the output conveyor comprises weighing means to weigh meat cuts after deboning and prior to trimming.

In one case each meat trimming station comprises an input gate through which meat to be trimmed at the trimming station is delivered.

In one case at least some of the trimming stations are dedicated to particular primal meat cuts. In some cases all of the trimming stations are dedicated to particular primal meat cuts.

In one case an input gate at a trimming station is opened in response to the approach of a primal 30 cut associated with the trimming station. The system may comprise gate operating means for opening the gate in response to the approach of a primal cut associated with the trimming station.

In one case each trimming station comprises an outlet for fat, an outlet for meat, and at least one outlet for trimmings. There may be a first outlet for trimmings having a low content of visible meat and a second outlet for trimmings having a high content of visible meat. The outlets may be arranged side-by-side adjacent to an operator table.

In one case each trimming station comprises a trimming interface means. The trimming interface 5 means may comprise entry means for entering data relating to the cut trimmed at the station. In one case the trimming interface means provides directions to the operator at the trimming station.

In one case the system comprises a trimmed output conveyor onto which meat, fat and trimmings from the primal(s) trimmed at the trimming station are delivered. The meat, trimmings, and fat may be delivered sequentially onto the trimmed output conveyor. The system may comprise a control means for spacing apart the delivery of the meat, trimmings and fat from a primal so that gaps are provided on the trimmings output conveyor between the meat, trimmings and fat.

In one case the system comprises weighing means on the trimmed output conveyor for individually in-line weighing meat, trimmings and fat from a primal.

In one case the trimming station comprises a bone outlet for removal of trimmed bones from the primal to a trimmed bone conveyor for delivery to a bone output conveyor. Each trimming station may include a bone outlet.

In one case the system comprises a quality control station to which trimmed meat is directed from the trimmed output conveyor for inspection. There may be feedback means to provide outputs from the quality control station to a control system and/or to an operator at a trimming station.

In one case the quality control station comprises a static inspection station. There may be a directing means for directing the inspected trimmed meat back onto the output conveyor.

In one embodiment the quality control station comprises an inspection conveyor along which the trimmed meat is led during at least portion of the inspection.

In one case the system comprises :a weighing station for weighing the fat trimmings; a scanner conveyor; first directing means for directing the fat, trimmings with low visible lean meat content and trimming with high visible lean meat trimmings from the output conveyor to the scanner conveyor; a scanner through which the fat, trimmings with low visible lean meat, and trimmings with high visible lean meat are led from the scanner conveyor to determine the fat content thereof; and second directing means to deliver the fat and trimmings from the scanner into a container dependent on the weight and fat content thereof.

In one case the scanner comprises a tunnel through which the fat and trimmings are led along the scanner conveyor. The scanner may comprise an X-ray scanner, or an infra red scanner.

In one case the system comprises third directing means for directing the meat cuts to a packaging station prior to delivery of the fat and trimmings through the scanner.

In one embodiment the system includes a primal meat processing system.

The primal meat cut processing system may comprise:a primal meat trimming, dividing and separating station to provide individual primal muscles; an output conveyor, onto which the individual primal muscles are delivered; an input weighing system for weighing the primal muscles; a membrane releasing station at which at least part of the membrane attached to the primal muscle is released / removed; a final trimming station for final removal of fat and/or membrane; and an output weighing station for weighing and recording individual membrane-removed primal muscles.

There may be a terminal at the output weighing station for inputting data relating to the individual membrane removed primal muscles.

In one case the membrane releasing station comprises an automatically operated membrane 10 releasing machine. The membrane releasing station may comprise a manually operated membrane releasing machine.

In one case the primal meat cut processing system comprises a packaging station downstream of the final weighing station. The primal meat cut processing system may comprise a dicing station downstream of the final weighing station.

In one case the system comprises a plurality of meat packing stations and trimmed meat output conveyors for delivery of meat from the trimming stations to the packing stations.

Also described is a method for deboning a cattle carcass comprising the steps of:providing an overhead deboning track for a plurality of hooks; delivering cattle quarters sequentially to a deboning line, having a weighing station, a 25 plurality of deboning stations, and a plurality of primal cut removal stations; hanging each quarter on a separate hook at an entry to the deboning line; moving the hooks sequentially through each of the weighing, deboning, and primal cut 30 removal stations, the quarters having the same set residence time at each of the deboning and primal cut removal stations; removing first meat cuts from the quarter at a first primal cut removal station; releasing and/or removing first bones from a quarter at a first deboning station; removing second meat cuts from the quarter at a second primal cut removal station; and releasing and/or removing second bones at a second deboning station downstream of the first removal station.

In one case the method comprises :providing a carcass comprising two sides, each side having a fore quarter and a hind quarter; splitting the side to provide a fore quarter and a hind quarter; and delivering the quarters sequentially to the deboning line.

The method may comprise removing third meat cuts from the quarter at a third primal cut removal station downstream of the second deboning station.

In one case the method comprises moving the hooks simultaneously along the track to advance the quarters through the deboning and primal cut removal stations.

In one case the method comprises advancing the hooks at a time interval of from 20 to 120 seconds. The method may comprise advancing the hooks at a time interval of from 30 to 60 seconds.

In one case the method comprises providing a tracking tag for the quarters of the carcass. The method may comprise scanning the tag at an input weighing station and optionally at some or all of the primal cut removal stations.

In one case the method comprises inputting primal cut removal data to interfaces at the primal cut removal stations.

In one case the method comprises delivering meat cuts from the primal meat cut removal stations onto the meat transfer conveyor. The individual meat cuts may be weighed on the transfer conveyor.

In one case the method comprises monitoring the meat cuts on the transfer conveyor and delivering a meat cut from a primal meat cut removal station onto the transfer conveyor when a gap on the conveyor is presented to the primal cut removal station.

The method may comprise delivery of bones from the deboning stations to the bone transfer conveyors.

In one case the method comprises providing a carcass side suspended from the ischium. The method may comprise suspending a hindquarter of the carcass side by the achilles tendon prior to splitting of the side; the hindquarter and forequarter being suspended from hooks on separate rails; and delivering the fore quarter and the hindquarter from the separate rails sequentially onto the deboning track so that the forequarter and the hindquarter from the carcass side are delivered sequentially to the deboning track. The method may comprise preventing movement of a quarter between stations.

The method may further comprise leading meat cuts from the meat cut transfer conveyor to one of a plurality of trimming stations.

In one case each of the trimming stations comprises an access gate and the method comprises opening the access gate of a trimming station in response to the arrival at the gate of a primal cut associated with that trimming station.

The case may comprise trimming the primal meat cut at the trimming station to divide the meat cut into lean meat, fat, and fat with visible lean meat attached and delivering the lean meat, fat, and fat with visible lean meat to associated outlets from the trimming station. In one case the method comprises delivering a lean meat cut, fat and fat with visible lean meat attached from the outlets onto a common output conveyor. The lean meat cuts, fat and fat with visible lean meat attached from a primal meat cut may be sequentially delivered onto the output conveyor.

In one case the method comprises maintaining a gap on the output conveyor between each of the lean meat cut, fat and fat with visible lean meat attached. In one case the fat with visible lean meat attached is divided into a first outlet for meat with a high visible lean meat content and a second outlet for meat with a low visible lean meat content.

In one case wherein the trimming station comprises a bone outlet and the method comprises delivering the bone from the primal meat cut to the bone outlet and delivering the bone along a trimmed bone output conveyor to a bone transfer conveyor.

The method may comprise presenting data regarding the meat cut to an interface at the trimming station. The method may comprise entering data regarding the meat cut using the interface.

In one case the method comprises providing data regarding the trimming of the meat cut to the operator at the trimming station.

There may be in-line weighing of the meat, trimmings and fat associated with a primal meat cut.

In one case the method comprises directing trimmed meat from the output conveyor to a quality control station, and providing outputs from the quality control station to a controller and/or an operator at a trimming station. The meat cut may be conveyed along a quality control conveyor during inspection.

In one case the method comprises trimming, dividing and separating individual primal muscles from an input meat cut at least one of the trimming stations, delivering the individual primal muscles onto the output conveyor, and directing the individual muscles to an individual muscle trimming station. The method may comprise releasing membrane from the individual muscle and final trimming of the muscle to remove fat and/or membrane at the individual muscle trimming station. In one case the method comprises weighing and recording individual membraneremoved primal muscles. Individual primal muscles may be packed downstream of the weighing station.

The method may comprise dicing an individual primal muscle downstream of the weighing station.

In one case the method comprises directing fat and trimmings with visible lean meat from the output conveyor to a scanner conveyor, conveying the fat and trimmings through a scanner to determine the fat content thereof, and directing the fat and trimmings from the scanner conveyor into a container dependent on the weight and fat content thereof The fat and trimmings may be led through an x-ray scanner, or an infra red scanner.

Also described is a primal meat cut processing system comprising:a primal meat trimming, dividing and separating station to provide individual primal muscles; an output conveyor, onto which the individual primal muscles are delivered; an input weighing system for weighing the primal muscles; a membrane releasing station at which at least part of the membrane attached to the primal muscle is released I removed; a final trimming station for final removal of fat and/or membrane; and an output weighing station for weighing and recording individual membrane removed primal muscles.

The primal meat cut processing system may comprise a terminal at the output weighing station for inputting data relating to the individual membrane removed primal muscles.

In one case the membrane releasing station comprises an automatically operated membrane releasing machine.

In one case the membrane releasing station comprises a manually operated membrane releasing machine.

There may be a packaging station downstream of the final weighing station. There may be a dicing station downstream of the final weighing station.

Also described is a meat processing system comprising: 5 a plurality of meat trimming stations, each trimming station comprising a first outlet for fat, a second outlet for trimmings having a low content of visible lean meat, a third outlet for trimmings having a high content of visible lean meat, and a fourth outlet for meat cuts; an output conveyor onto which the fat from the first outlet, the trimmings with low visible lean meat content from the second outlet, the trimmings with high visible lean meat content from the third outlet, and the meat cuts from the fourth outlet are delivered; a weighing station for weighing the fat, trimmings and meat cuts; a scanner conveyor; first directing means for directing the fat, trimmings with low visible lean meat content 20 and trimming with high visible lean meat trimmings from the output conveyor to the scanner conveyor; a scanner through which the fat, trimmings with low visible lean meat, and trimmings with high visible lean meat are led from the scanner conveyor to determine the fat content thereof; and second directing means to deliver the fat and trimmings from the scanner into a container dependent on the weight and fat content thereof.

In one case the scanner comprises a tunnel through which the fat and trimmings are led along the scanner conveyor. The scanner may comprise an X-Ray scanner, or an infra red scanner.

In one case the meat processing system comprises third directing means for directing the meat cuts to a packaging station prior to delivery of the fat and trimmings through the scanner.

Also described is a meat processing system comprising:a meat cut delivery conveyor for delivery of meat cuts; an input weighing means for in-line weighing of meat cuts; a plurality of trimming stations; an output conveyor onto which meat, trimmings and fat from a meat cut are delivered; an output weighing means for in-line weighing of the meat, trimmings and fat associated with a trimmed meat cut; a quality control station to which trimmed meat is directed from the output conveyor for inspection; and feedback means to provide outputs from the quality control station to a control system and/or to an operator at a trimming station.

In one case the quality control station comprises a static inspection station.

There may be a directing means for directing the inspected trimmed meat back onto the output conveyor.

In one case the quality control station comprises an inspection conveyor along which the trimmed meat is led during at least portion of the inspection.

Brief Description of the Drawings The invention will be more clearly understood from the following description thereof, given by way of example only, in which: Fig. 1 is a plan view of a carcass processing system of the invention; Fig. 2 is a plan view of an infeed system; Fig. 3 is an elevational view of the infeed system; Fig. 4 is an elevational view of the infeed section of the deboning system; Fig. 5 is a plan view of a deboning system of the invention; Fig. 6 is a plan view of a meat trimming system of the invention; Fig. 7 is a plan view showing two meat trimming stations; Fig. 8 is an isometric view at one trimming station; Fig. 9 is an elevational view illustrating transfer of meat cuts, trim and bone from a trimming station onto a trimmed output conveyor; Fig. 10 is an isometric view of a meat transfer system associated with one trimming 20 station; Fig. 11 is a plan view of quality assurance and membrane removal stations; and Fig. 12 is a plan view of a fat scanning system used in the invention.

Detailed Description Referring to the drawings there is illustrated a cattle carcass processing system comprising a 30 carcass input system 1, a deboning system 2, a trimming system 3, a quality control inspection system 4, a primal membrane removal system 5, and a packaging system 6.

Referring in particular to Figs. 2 to 4 the input system 1 comprises an overhead chiller conveyor 10 along which carcass sides (also referred to as half carcasses) 11 are delivered to a transfer station 12. The carcass sides 11 are initially suspended from the ischium. At the transfer station 12 an operator 7 on a height adjustable work platform inserts a support hook 13a into the achilles tendon of the carcass hindquarter. An operator 8 splits the carcass side into a hindquarter 14 and a forequarter 15. Another hook 13b is inserted into the forequarter 15. The hindquarter 14 is suspended on a high level rail 16 and the forequarter 15 is suspended on a lower level rail 17. The different rail heights accommodate the differences from ground level of the points of suspension between the forequarter 15 and the hindquarter 14.

The hindquarter rail 16 is lowered and the forequarter rail 17 is raised and the rails 16, 17 merge 10 into an infeed rail section 19 at a working height of 2.4 metres. The hindquarters and forequarters are alternatively indexed into a single line using a pneumatic switching arrangement. At an indexing station 20 alternate forequarters 14 and hindquarters 15 are delivered onto a main processing rail 21. Empty chiller rollers are returned to an abbatoir along a return rail 9.

Referring especially to Fig. 4 the deboning system 2 comprises the overhead rail 21 along which a plurality of carriages 22 run. Each carriage 22 carries a support hook 13 for a carcass quarter. The carriages 22 are located between a pair of dogs 23, 24. A leading dog 24 is used to stop the carriage 22 and a trailing dog 23 is used to drive the carriage 22 forwards. The dogs 23, 24 are suspended from a moving chain 25. The dogs 23, 24 are pivotal on arms 27 carried by the endless motor driven chain 25.

Thus, a half carcass 11 from the chiller travelling along the chiller conveyor 10 is suspended from the ischium bone. At the transfer station 12 the half carcass 11 is re-suspended from the achilles tendon to facilitate deboning and prevent damage to valuable muscles such as the beef fillet (psoas major). The four quarters from a single carcass may be assembled at the indexing station 20 for delivery to the deboning system 2. Thus, the four quarters from a single cattle carcass may be presented in sequence to the boning line.

Each of the sides 11 and/or quarters 14, 15 has a unique identifier or tag 29. The arrangement facilitates traceability and tracking. An incoming quarter 14, 15 is weighed using a load cell and the weight and other details are introduced into the system by scanning the unique bar-coded label 29 attached to the quarter while it is weighed. This animal identification is tracked and traced throughout the remainder of the process. The beef quarters 14, 15 are subsequently deboned using electromechanical de-boning machines. Meat cuts and/or bones are removed.

The system optimises the various operations for maximum efficiency. Beef quarters 14, 15 are 5 introduced into a mechanised overhead conveyor line 21 which indexes the quarters past eight or more workstations in a stop-start fashion. The conveyor line 21 minimises wasted operator movement in retrieving and removing beef quarters from their station while pacing workers to complete their tasks in a defined time period.

The deboning system comprises an input station 30 at which the tag 29 is read and recorded and also the weight of the quarter is recorded. From the input station 30 a quarter is delivered to a preparation station 31 at which an operator scribes various marks on the bones to aid removal. At the next station 32 (the first primal cut removal station) some primal cuts are removed and delivered to a primal rib processing station 33 and various preparation tasks are preformed. The quarter is then advanced to a first de-boning station 34 at which SRM bone is removed using an electro mechanical pulling system 34a. The SRM bone is delivered into a chute 35. The partially de-boned quarter is then advanced to a further preparation station 36 at which further cuts are made. At the next station 37 (the second primal cut removal station) further cuts are made and primal cuts removed at this station are transferred to a loin reception station 38. At a final bone removing station 39 final major bones are removed using an electromechanical drop rail system 39a. The removed bones are delivered into a safe bone chute 40. Finally, the deboned quarter is delivered to a primal cut removal station 41 (the third primal cut removal station) at which various primal cuts are removed and delivered onto a main output conveyor 42.

In more detail, at the rib processing station 33 the rib bones are trimmed by operators 43, 44 and the trimmings are delivered onto an output product conveyor 45. There is also an inlet buffer 33a at the rib processing station 33. Bones removed at this station are delivered into an appropriate bone chute, SRM bones being delivered into separate chutes than safe bones. At the station 38 further bones are also removed and delivered into an appropriate bone outlet chute.

SRM bones from the various SRM outlet chutes 35 at the de-boning stations are delivered to a . dedicated SRM conveyor 47 and 48 for discharge though a discharge chute 49 to a separate container for removal/disposal.

Safe bones are delivered from the various safe bone chutes 40 to a dedicated safe bone conveyor 50 and 51 and delivered down a safe bone chute 52 to a separate container for removal. Various safe bones which are removed at the trimming stations described below are delivered via trim bone conveyors 53 to the main safe bone conveyor 50.

The carriages 22 which carry the support hooks 13 are all moved simultaneously so that as a support hook 13 which has a bone or a quarter on which deboning and cutting operations are completed leaves the final primal cut removal station 41 a new quarter enters the input station 30, the quarter which was at the input station 30 is automatically delivered to the next station 31, the quarter which was at the station 31 is automatically delivered to the next station 32 and so on. In this way the system ensures that the quarter has the same set residence time at each of the stations. In the invention the indexed overhead conveyor 21 introduces and removes quarters from each workstation at a defined pace. This paces operatives as well as eliminating wasted operator movement to transfer the next quarter. Typically the residence time at each station is from 20 to 120 seconds, typically 30 to 60 seconds.

There are a series of interlock safety features and emergency stop override buttons to prevent carriages 22 from moving until all process equipment used at a particular station is in a safe home position. This prevents possible damage to equipment and injury to operators. There are also visual and audible alarms to indicate that the carriages 22 are about to commence movement and/or are moving.

After carcass processing empty support hooks 13 are washed and sterilised at a sterilising station 100. The washed empty carriages 22 carrying the support hooks 13 are re-introduced to the start of the process where the support hooks 13 are attached to hindquarters and forequarters.

Removed boneless beef cuts are introduced into the main flow conveyor 42 at a pre-defined rate using in-feed conveyors. This involves the operator placing the cut onto an in-feed from which it is delivered onto the main flow conveyor 42. In this way, the identity and location of the cut is continuously controlled on the main process conveyor.

Removed bones are classified into SRM bone and safe hone. The SRM bones are delivered into various infeed chutes, onto the SRM bone conveyor 47 for batch weighing in a hopper 49 from which the SRM bone is discharged into a SRM bone truck for removal. Safe bone is delivered through various infeed chutes onto a main bone conveyor 50 for batch weighing in a hopper 52 from which the bone is discharged into a truck for removal. In this way the bones are handled efficiently and safely. The weight of the bones is recorded to facilitate yield calculations.

There is a common meat output conveyor 42 for receiving meat cuts removed at each of the primal cut removal stations. Each cut removal station has a feed conveyor with an exit gate through which a meat cut is delivered onto the output conveyor 42. The system comprises means to detect a predetermined gap on the meat output conveyor 42 and an operating means for opening the gate to allow the meat cut to be delivered into the gap on the meat output conveyor 42. The various meat cuts are spaced-apart along the conveyor 42 with a gap of typically 600mm to 1000mm therebetween.

There is an interface at each of the primal cut removal stations. The interface may provide product ID and cutting instructions to the operator. The operator also enters details of the cut removed when he presents the cut to the outfeed conveyor. Quarter tags 29 may also be rescanned if required.

Referring especially to Figs. 6 to 10 individual meat cuts on the meat output conveyor 42 are weighed by an in-line weigher 60. The meat cuts are delivered to the trimming system which comprises a plurality of meat trimming stations 61 at least some of which are dedicated to trimming of particular primal meat cuts. Each of the trimming stations 61 has an input gate 62. When a meat cut associated with a particular trimming station 61 approaches the station the gate 62 opens to deflect the cut from the conveyor 42 to the trimming station 61. At the trimming station 61, the operator trims the meat and delivers fat 63, low visible lean trimmings 64, high visible lean trimmings 65, and meat 66 into separate hoppers which are arranged side by side adjacent to the working table at the trimming station 61. There is also an interface 69 at each trimming station which is used to record details of the cut and/or to provide instructions for trimming the cut to the operator. Each trimming station also has a bone outlet 67 through which bone is delivered onto the trimmed bone conveyor 53 which conveys the bone to the main bone conveyor 50. Each trimming station 61 comprises an adjustable height work platform 68 to maximise ergonomic efficiency. The control system monitors operator productivity and ensures there is always a supply of primals for trimming at each trimming station 61.

Boneless beef primals from the paced de-boning system 2 enter the primal trimming system 3. Primals are weighed on a dynamic scale 60 so that the de-boning yield can be derived. In addition, primals can be sorted by weight ranges at this stage based on customer specifications. Weighed primals are transported on an intelligent conveyor 42 and diverted into one of eighteen trimming stations 61 using pneumatic gates 62. At each trimming workstation 61, the operator receives cut identification and butchery information via the interface 69. The operator trims the primal to the indicated specification. Trimmed primal(s) 66, low visible lean trimmings 64, high visible lean trimmings 65, fat 63 and bone 67 are placed into individual buffers for that primal. Successful completion of the task is confirmed by the operator using the interface 69. All products (except bones) are then automatically released from the buffers onto a take away intelligent trimmings conveyor 90 so as to maintain traceability of all products from that primal. The delivery of the products onto the trimmings conveyor 90 is timed to maintain gaps between the products on the conveyor 90. The individual products from the trimming station 61 are weighed on a dynamic weigh scale 95 and registered into the line control system to provide real time yield and production speed control to a quarter.

Referring to Fig. 11 butchery products from the trimming line 90 may be diverted to one of two quality assurance stations 70, 71 according to pre-determined protocol for inspection. At each station 70, 71, product identification and instructions are relayed to the operator via a terminal. A history of quality non-conformances is maintained and feedback provided. An intelligent flow line directs primals and trimmings to/from designated quality assurance stations 70, 71 so that the weight, identification and quality attributes of incoming primals/trims will be measured. This data will be continually fed to a central computer system which will give real time quality assurance data per primal/trim type and trimmer to the production supervisor(s). The first quality control station 70 is a static inspection station at which the trimmed cuts are inspected and feedback is provided via a terminal 73. After static inspection the meat cut may be reintroduced onto the main trimmed product conveyor 90. The second quality control station 71 comprises an inspection conveyor 72 to which meat cuts are led for inspection. Again, feedback and inputs are provided by a terminal 74. The output from the quality inspection station 71 may be directly packaged.

Due to increasing consumer demand for 100% lean beef cuts (e.g. cubed meat), some trimmed primals are diverted to a membrane skinning line 80 which is also illustrated in Fig. 11. Cuts are diverted by a gate 86 and diverted cuts are automatically fed into a continuous skinning machine 81, Cylindrical shaped primals are fed to a manual skinner 82. Skinned pieces exit the skinner and are led by a conveyor 81a to a main conveyor 83 to workstations 85 where the lean cuts are inspected and final trimming such as removal of any membrane not removed by machine is performed. Skinned cuts are delivered onto an overhead conveyor 84. All skinned cuts are transported on the conveyor 84 to the final packing station 88. Here, an operative identifies the skinned cut and registers this information along with its weight using a weigh scale and terminal 87. The product is then manually packed in vacuum pouches. The arrangement enables the real time control of skinning yield by cut type. An intelligent flow line directs primals and trimmings to/from a designated skinning arrangement so that the weight and identification of incoming primals and outgoing skinned muscles will be measured. This data will be continually fed to a central computer system which will give real time yield and throughput data per primal type to management.

The outputs from the trimming stations 61 are directed to the packing system 6 which comprises a plurality of meat packing stations for various cuts and trimmings of meat.

Un-skinned primals, lean trimming, fat and major membranes are fed to a packing arrangement. They are diverted in a pre-determined fashion so that they are packed into vacuum pouches or bulk packed into cartons/totes.

Referring to Fig. 12 lean trimmings and fat are directed from the main trim conveyor 90 by a gate 95 to a fat content control system 96 to ensure product sold by percentage of fat is accurate thus maximising output value. Trimmings and fat are conveyed as separate small batches along a conveyor 97 through an X-ray tunnel 98 which measures fat content to an accuracy of less than 1%. These small batches are then weighed on a dynamic scale 99 and fed to a multi-station sorting gate arrangement at which larger batches of defined weight and fat content are built up. These batches are packed into bags, totes or the like.

The intelligent flow line directs primals and trimmings to/from a designated packing arrangement so that the weight and identification of incoming primals/trims and outgoing packs will be measured and controlled. This system enables each primal to be individually labelled with animal ID and weight information.

Traceability is maintained so that products can be packed with a label identifying such items as animal identification (for primals); batch code (for trimmings, fat, membrane, etc); product weight; % chemical fat; butchery and packing operative identification; farmer details; production and use by dates; bar code; unique pack number.

An intelligent flow line directs primals and trimmings to/from designated trimming stations so that the weight and identification of incoming primals and outgoing primals/trims is measured. This data is continually fed to a central computer system which gives real time yield and throughput data per primal and quarter to management.

De-boning is separated from trimming which results in minimal contamination. In order to maintain traceability, no product touches another product until it is packed thus avoiding cross contamination.

The system enables real time control of product yield and labour productivity which results in higher margins and lower costs for de-boning.

The system of the invention provides optimum carcass handling and meat processing to minimise labour content while providing real time yield, production and traceability control at high production rates. Primals can be traced to individual quarters.

In the invention there is real time monitoring of the various processes which allows corrective action to be initiated quickly. The system also facilitates optimisation of the quarter yield by butchering beef primals so as to maximise yield based on customer orders and quarter characteristics such as fat cover, conformation, sex and weight.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail within the scope of the invention.

Claims (12)

Claims

1. A meat processing system comprising:5 a meat cut delivery conveyor for delivery of meat cuts; an input weighing means for in-line weighing of meat cuts; a plurality of trimming stations; an output conveyor onto which meat, trimmings and fat from a meat cut are delivered; an output weighing means for in-line weighing of the meat, trimmings and fat 15 associated with a trimmed meat cut; a first quality control station; means for diverting trimmed meat from the output conveyor to the first quality 20 control station for inspection; feedback means to provide outputs from the first quality control station to a control system and/or to an operator at a trimming station; 25 a directing means for directing the inspected trimmed meat from the first quality control station back onto the output conveyor; a second quality control station comprising an inspection conveyor along which meat cuts are led for inspection; and feedback means to provide outputs from the second quality control station to a control system and/or to an operator at a trimming station; and wherein the second quality control station is in series with the first quality control station and the output from the second quality control station is directly packed.

2. A meat processing system as claimed in claim 1 wherein the first quality control station 5 comprises a static inspection station.

3. A meat processing system as claimed in claim 1 substantially as hereinbefore described with reference to the accompanying drawings. 10

4. A system as claimed in any of claims 1 to 3 wherein each meat trimming station comprises an input gate through which meat to be trimmed at the trimming station is delivered.

5. A system as claimed in any of claims 1 to 4 wherein at least some of the trimming 15 stations are dedicated to particular primal meat cuts.

6. A system as claimed in claim 5 wherein all of the trimming stations are dedicated to particular primal meat cuts. 20

7. A system as claimed in claim 5 or 6 wherein an input gate at a trimming station is opened in response to the approach of a primal cut associated with the trimming station.

8. A system as claimed in claim 7 comprising gate operating means for opening the gate in response to the approach of a primal cut associated with the trimming station.

9. A system as claimed in any of claims 1 to 8 wherein each trimming station comprises an outlet for fat, and outlet for meat, and at least one outlet for trimmings.

10. A system as claimed in claim 9 comprising a first outlet for trimmings having a low 30 content of visible meat and a second outlet for trimmings having a high content of visible meat.

11. A system as claimed in claim 9 or 10 wherein the outlets are arranged side-by-side adjacent to an operator table.

12. A system as claimed in any of claims 1 to 11 wherein each trimming station comprises a trimming interface means.