ATHENA boosts consistency and efficiency at Cedrob

The ATHENA system has been fully integrated into Cedrob’s product flow, operating in conjunction with RoboBatcher and packaging equipment. This integrated setup ensures a continuous and synchronized process flow from breast deboning to portioning, batching, and final packing.

Great consistency

Before ATHENA, Cedrob’s breast deboning relied on manual or semi-automated harvesting. Łukasz Olszewski notes that ATHENA offers great stability and predictability, eliminating the variability that inevitably comes with manual harvesting. ATHENA keeps delivering the same performance and yield level, independent of operator skills. “ATHENA’s precise cutting minimizes losses and provides stable, repeatable results with fillets consistent in quality. The fully automated deboning process means a steady throughput and reduced variability, contributing to smoother operations overall.” 

Less labor needed

For Cedrob, another clear improvement is the reduced labor requirement, without any negative effects on yield or product consistency. The whole ATHENA system only needs two operators to put every breast cap into the loader, an ergonomically convenient and easy operation with no force required. 
Łukasz Olszewski talks about the workforce needed since implementing ATHENA: “ATHENA means fewer employees are required on the line, and the work has become easier and less physically demanding. The reduction in repetitive manual cutting tasks has significantly improved ergonomics and working conditions. Automated harvesting is more consistent, predictable and less dependent on operator skills. It reduces variability and physical strain compared to manual harvesting.” For Cedrob, reduced dependence on manual labor also has positive effects on process stability and planning capabilities.

Flexibility across product types and sizes

Adam Gebert is happy with the way ATHENA handles the incoming variety in chicken types and weights. “The system automatically adapts to different bird sizes and weights, maintaining cutting accuracy across varying product specifications. Switching between different product recipes is handled smoothly, enabling us to make quick adjustments and avoid downtime.”

User-friendly operation

Cedrob describes ATHENA as a user friendly and intuitive system. “After a short training period, our operators can manage it efficiently. The touchscreen makes it easy to have full control of precise settings for all types and weights, consistent cutting quality and stable performance,” says Adam Gebert, who finds it helpful to operate the machine directly from the screen using recipes. “This helps us achieve the best possible results. Manual recipe adjustments are minimal, as most settings are handled automatically. Only occasionally, we need some fine-tuning.”

Valuable real-time performance insights

ATHENA collects data and tracks products through the deboning process. Using this data, integrated SmartBase machine software gives real-time insight into relevant parameters about the machine’s performance and health status. Cedrob makes good use of this data. “We use the data related to product carriers and it is helpful. These insights help us monitor the process and maintain stable performance,” says Adam Gebert.

Reliable system

In terms of maintenance and reliability, ATHENA has shown it plays a dependable role in Cedrob’s secondary processing. Łukasz Olszewski concludes, “Maintenance requirements fit in well within Cedrob’s standard procedures and support from JBT Marel has always been professional and responsive. Any issues were handled quickly and effectively.”