Software streamlines every factory upgrade

Data-driven processing

Adding ‘intelligence in terms of software is the best way to integrate new options into an existing processing line without having to make big investments. Poultry processing is a highly dynamic industry and it would be very tough for poultry processing companies to operate without the support of an intelligent software platform. In such a complex environment, Marel’s plant-wide software solutions make it possible to think smart and act quickly. Data-driven processing is critical to making informed decisions that can be implemented with very little notice. Marel offers all the tools required to give the resilience and speed-to-market processors need to be competitive in the industry. Across all the departments in the poultry processing plant, Marel Software Solutions connects and serves the needs of the staff on the factory floor or in the control room. Incorporating data gathering into a processing plant necessitates the installation of additional hardware, such as sensors and cameras. From a software perspective, implementing data gathering and data processing is quite feasible.

Comprehensive software solution

Marel Software is fully prepared to be integrated into existing lines. Marel Software offers a highly flexible and fully scalable production control software that empowers processors to efficiently control, monitor and improve every aspect of the production process, from live bird handling, up to the dispatching orders and QC processes. It’s an entirely scalable platform that can be added to according to the processors’ needs and requirements. At any given time, a processing plant can start implementing Marel Software, for instance when an upgrade to a higher capacity takes place.

It’s possible to start controlling the weighing, packing, labeling, pricing and palletizing processes with end-of-line solutions such as Final Goods Manager, Inventory, Weighing and Labeling and Packing. Using these software solutions, food processors can take complete control of their value chain: they can maximize yields, throughput and uptime and reduce costs, stock and give-away.

Plant-wide control

This software package can be extended to include Traceability, Order Manager,  Quality Control and IMPAQT, offering even more control of plant-wide processes.
Optimized traceability through the whole production chain is at the forefront of food safety. The traceability functionality links every process step of the production chain to ensure that products can be traced back to their source. Quick action can be taken to minimize the impact of recalls.

Real-time insight

Software Solutions are available for every role in the factory, from Quality Control Manager to Production Planner and Technical Manager, offering real-time dashboards for paperless control of every production process. If an incoming flock varies in weight, if a machine shows a drop in performance, if customers suddenly change their order, or if a recipe needs to be changed, Marel Software gives real-time insight into how processes can be adjusted to solve the issue.

Profitable form

Implementing Innova PDS (Product Distribution System) in an existing poultry processing plant is an almost indispensable step for growing processors. Processors want to match available products to their customer orders as efficiently and cost-effectively as possible. They want to get the most out of their A-quality products and give a profitable destination to the remaining products while maximizing carcass balance and minimizing giveaway. Innova PDS is an in-line logistic management system that oversees and controls all processes from shackling to cut-up. With the help of sensors, weighers and cameras, Innova PDS gathers, records and manages all relevant data, following each product as long as it’s in the overhead conveyor. Based on this information, Innova PDS efficiently guides each product to the optimal downstream process, ensuring it is transformed into its most profitable form. By aligning products with customer orders, it optimizes daily production.

Unleash full potential

Implementation of the Innova IMPAQT module (Intelligent Monitoring of Performance, Availability and Quality Trends) will unleash the full potential of a Marel production line. Innova IMPAQT measures the trends in losses in the process over time; it’s the perfect analyzing, signaling and optimizing tool which starts in the primary process. Optimally improved production processes and highest added value will be the result.

Processors who decide to implement Marel Software into their existing daily operations will, from then on, know exactly what’s happening in the factory. They’ll have a stable digital component at their fingertips, on which everybody can rely. The end result will be improved process efficiency, increased operational uptime and enhanced alignment between arriving broiler flocks and pending customer orders.