Meat and compete

The automated meat processing technology includes a pilot leg roller, seen here installed on a static test rig at Auckland Meat Processors in South Auckland. Pictured, from left, Jason van Beurden (IRL), Geoff Bates (IRL), Chris Stiles (AMP), Chris Lennox (IRL).

IRL, together with Realcold Milmech, is a lead research partner in the $15m million project, which began just over a year ago and will save the industry millions of dollars by automating the early stages of sheep processing. The initiative is funded by nine meat companies that have banded together to form Ovine Automation Limited (OAL), and the Foundation for Research, Science and Technology.

The project is ahead of schedule with trial technology installed in plants in both the South and North islands. Equipment developed so far by IRL includes a pilot leg roller, a gas de-pelter, which uses pressurised gas to release pelts from carcasses, and an intelligent Y-cutter robot. The Y-cut is an industry term for the cut that opens the fleece on the front legs of a sheep in preparation for pelt removal.

Realcold Milmech has two robots, dubbed Alice and Rita by staff on the plant floor, operating in production at a Southland plant to automate brisket cutting and remove the internal organs of sheep. Other robots will be installed further down the track.

The system is modular, with equipment expected to be progressively released for sale from early in 2011. Geoff Bates, IRL account manager Engineering & Applied Physics, says being adequately funded, thinking laterally, and collaboration with plenty of industry partner input, have been central to the success of the project.

“With previous automation R&D for the meat processing industry, we’ve tended to pick the hardest jobs and underquote on the cost. Kiwis are always trying to do things for as little as possible but ultimately it is cheaper to invest $300,000 and end up with a working product than to invest $100,000 and end up with nothing.”

Rather than building robots from scratch, the project partners are purchasing basic units ready-made, and putting the creative effort into inventing the components needed for the specific job in mind. They’re also being pragmatic, says Bates, and automating only the parts of the process that can be done better by machines.

But the way the industry and R&D partners are working together is arguably the most standout feature of the project. Realcold Milmech R&D manager Peter Loeber says in more than 30 years in the meat processing industry, he has never before seen such a degree of cooperation.

"Everyone has put aside differences and is contributing their ideas and skills, right down to those actually doing the processing.

For them, installing robots has meant a new layout and doing some things differently but the changes have been met with willingness and a positive attitude.”

OAL manager Richard McColl agrees, saying the institutional knowledge of people in all parts of the industry is being harnessed and fed into the R&D.

“IRL, for example, has been able to work alongside production and engineering staff from within meat processing plants for the first time, solving problems collectively and ensuring that what they come up with will work in the plant.”