Marel introduces artificial intelligence in poultry processing
Until now, vent cutting has relied heavily on the skill of the operator. However, advancements in technology now make vent cutting more efficient and reliable. A perfect example of this innovative progress, representing a significant leap forward, is Marel’s VC-i, the world’s first intelligent vent cutter using artificial intelligence.
Vent cutting is a crucial step in poultry processing and involves removing the cloaca and correctly positioning it over the back of the broiler carcass. This process must be performed with utmost precision to ensure the highest standards of hygiene and product quality. Until now, vent cutting has relied heavily on the skill of the operator, making it a labour-intensive process with inconsistent performance and quality, certainly with flock changes. Technological advancements such as Marel’s VC-I have made vent cutting more efficient and reliable.
Maintaining high performance during vent cutting is paramount because it is the very first operation inside the carcass in the processing plant, directly following the defeathering process. If this first step isn’t of the highest quality, the subsequent processes and machines in the line cannot correct this. Accurate vent cutting avoids soiling and ensures the quality of the final product. Achieving the right drilling depth to release the cloaca without damaging the intestines requires a delicate balance to prevent contamination and maintain product integrity.
Why does the process need digitalisation?
In today’s fast-paced and demanding poultry processing industry, relying solely on human skills to adjust machines is no longer sufficient. By integrating Pupil’s artificial intelligence, SmartBase internal machine software, advanced mechanical designs, and HMI touchscreen control, the VC-i offers numerous advantages. These include minimised human error, enhanced overall performance, real-time insights, user-friendly operation, and seamless interaction between recipe control and the machine’s mechanical components. This digital transformation brings consistency, precision, and efficiency to the vent-cutting process.
Enhanced technology and design
The VC-i features 20 newly-developed units capable of handling line speeds of up to 15,000 bph. Its advanced technologies ensures accurate drilling and precise product positioning, maintaining high product quality and hygiene standards. The open structure of the units, which includes a robust sliding rod, contributes to a lower cost of ownership by facilitating easy cleaning and reducing contamination risks by residues. Additionally, for improved user-friendliness, the replacement of units has become easier and faster.
Consistent performance across flocks and shifts
The VC-i automatically adjusts its settings based on pre-defined recipes selected via the HMI touchscreen. This eliminates the need for manual adjustments and guesswork, ensuring consistent and robust performance with minimal contamination risks across different flocks and shifts. The ability to maintain optimal parameters automatically, such as drill depth and product positioning into the units, greatly benefits the reliability of the process.
Prioritising hygiene
Since vent cutting is the first operation inside the carcass, maintaining the highest standards of hygiene and care at this stage is crucial. The VC-i’s design highly prioritises hygiene, with features such as a vacuum system that removes initial feces at the beginning of the intestines to prevent contamination. As we have seen, a careful and precise drilling process is the most effective way to maintain hygiene and prevent any form of soiling.
AI-powered performance measurement
Pupil (Precision unified processing with intelligent learning), the integrated AI vision technology, uses deep-learning algorithms to measure the performance of the VC-i. This system provides real-time insights into the machine’s performance and settings, eliminating the need for highly skilled operators to recognise and count the cloacas correctly hung over the back of the product, which pass by incredibly fast. Pupil’s objective and unbiased measurements ensure accurate and reliable performance data.
Actionable insights with SmartBase
SmartBase internal machine software provides real-time insights into the machine’s health status and performance, displayed on accessible dashboards that can be viewed on a touchscreen or remotely. Early warning alerts, at both machine level and unit level, enable proactive adjustments and maintenance. For instance, these alerts can indicate when performance drops below 96%. Consequently, an underperforming unit can be replaced during a break or after production, preventing potential line stops. This complete overview of the vent-cutting process eases decision-making and operational efficiency.
Water savings
At the infeed, a product detector identifies empty shackles and one-leggers, excluding them from performance measurements. If there is a longer sequence of empty shackles due to a production pause, the spray-cleaning of the drill units automatically stops, significantly saving water and reducing operational costs.
The Marel VC-i is a game-changer in vent cutting, offering unparalleled precision, hygiene, and efficiency. Its smart and advanced technologies ensure consistent performance, reduce the reliance on skilled labour, and provide valuable insights into the process.
WATCH the video below on Marel’s CV-i, the world’s first intelligent vent cutter using artificial intelligence…
Join 31,000+ subscribers
Subscribe to our newsletter to stay updated about all the need-to-know content in the poultry sector, three times a week.
