Dynamic Carcass Allocation in Poultry Cut-Up Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Poultry processing installations with two cut-up lines often face insufficient capacity issues, leading to reduced quality and yield, as they are typically set up to handle only two carcass size categories, resulting in inefficient allocation and potential manual reworking of carcasses.
Innovation Solution
Implementing a computerized production control system that grades carcasses into three size categories (small, large, and intermediate) and dynamically allocates them to available cut-up lines based on real-time capacity, allowing for more efficient distribution and reducing the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If only two cut-up lines are provided for processing poultry carcasses, then investment and operating costs are reduced, but processing capacity becomes insufficient leading to reduced quality and yield
Solution Approach 1:
The patent implements dynamic allocation of carcasses to cut-up lines based on real-time capacity status. The system continuously monitors the buffer status of each cut-up line and dynamically redirects carcasses from intermediate size categories to appropriate lines, transforming a static two-line system into a dynamic one that adapts to changing processing demands and prevents capacity bottlenecks
Solution Approach 2:
The system changes the parameter of carcass size categorization from traditional two categories to three categories (small, intermediate, large). This parameter change allows for more granular control and flexible allocation of carcasses to available cut-up line capacity, enabling the two-line system to handle varied carcass sizes efficiently without exceeding processing capacity
2Speed
If carcasses are allocated to cut-up lines based on simple weight categories, then allocation speed is maintained, but quality and yield reduce due to insufficient capacity management
Solution Approach 1:
The patent implements a feedback mechanism where the system continuously monitors the buffer status and capacity of each cut-up line. This real-time feedback enables the control system to make informed allocation decisions, directing carcasses to lines with available capacity while preventing overload, thereby maintaining both allocation speed and processing quality through dynamic adjustment
3Manufacturing precision
If a third cut-up line is added to increase processing capacity, then quality and yield are maintained, but investment and operating costs increase
Solution Approach 1:
The patent makes the existing two cut-up lines universal by enabling them to process multiple carcass size categories through dynamic allocation. The system allows cut-up lines to handle not only their primary size category but also intermediate categories when capacity is available, effectively transforming specialized lines into multi-functional units that maximize utilization without requiring additional equipment
4Manufacturing precision
If manual reworking of carcasses is performed to handle capacity issues, then quality can be maintained, but operator burden increases and efficiency decreases
Solution Approach 1:
The patent implements an automated self-service allocation system that monitors cut-up line capacity and automatically redirects carcasses from intermediate size categories to appropriate lines. This eliminates the need for manual operator intervention in capacity management, allowing the system to self-regulate carcass allocation based on real-time conditions while maintaining quality through proper routing
Data Source
AI summary
Method for processing slaughtered poultry, wherein oven-ready carcasses of slaughtered poultry are conveyed by a feed conveyor (2), said feed conveyor having an endless track and carriers (2a) that are moved along said track, the feed conveyor carrier being adapted to support one carcass suspended from its legs. Each individual carcass is subjected at least one of: ●—a determination of the individual carcass weight by a weighing device (4), ●—a determination of the individual carcass size by an imaging device. For dividing the carcasses into parts use is made of a first cut-up line (10) and a second cut-up line (20), wherein each cut-up line has an associated cut-up line conveyor (11, 21), said cut-up line conveyor having an endless track and carriers (11a, 21a) that are moved along said track, each cut-up line conveyor carrier being adapted to support one carcass suspended from its legs. Each cut-up line comprises one or more cutting devices (12, 22) arranged along the track, which one or more cutting devices divide a carcass supported by a cut-up line conveyor carrier into parts.