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In Ukraine, a conveyor and carcass-cutting equipment was created to transport raw meat in half-carcasses and quarters to personnel workplaces, with subsequent separation of meat from bones and varietal cutting (finishing). The line is equipped with a conveyor for discharging filled boxes as well as a roller conveyor for supplying empty containers. The advantage of its usage not only in large but also in medium-sized enterprises is the maximum improvement of production processes, increase in personnel productivity, and strict accounting of incoming raw materials on bones and grades after cutting.
Meat deboning equipment consists of a sawing section located at the beginning of the conveyor. At the sawing post, the half carcasses are divided into the necessary parts and then fed to the main line of the conveyor belt. A vertical position is the best way for preliminary cutting the half-carcass into pieces as it significantly speeds up the cutting process. The main conveying line consists of a frame made of stainless steel, a drive, a modular belt, and a pneumatic lifting system for the modular belt. Tables with removable tabletops, which serve as staff workstations, are fixed to the sides of the conveyor frame. The removable tabletops are made of polyamide. A roller conveyor is placed above the main conveyor belt for transporting empty containers to personnel workplaces. Under the main conveyor there is a conveyor for discharging filled containers, which allows staff to ship containers filled with meat without being distracted from the production process. Filled boxes move along the main line, pass onto an inclined conveyor, and end up on the operator’s table for weighing and entering information into the enterprise database. The dimensions of the conveyor and the number of workplaces are determined according to the customer’s wishes.
Pork half-carcasses are supplied to the sawing platform in a suspended state for rough cutting into large pieces. A vertical position cutting has a better effect on the speed and quality of cutting half-carcasses. Then, parts fall through the chute under the influence of gravitational forces onto the main meat supply conveyor. Due to conveyor belts, pieces of half-carcasses are moved to the workshop specialists who separate the meat from the bone. At the same time, large meat parts can be transported for further processing or stored in separate boxes. In the second option, the raw materials are sent for sale as fresh meat or used for production purposes.
The existing meat parts, separated from the bone, are moved further on the conveyor to varietal cutting and finishing. During the process, the pork is divided into 4 – 6 E2 boxes by the workshop staff. Each is located near the cutting table and auxiliary equipment for meat cutting. Next, the filled boxes are redirected by workers to a conveyor belt for removing the filled containers. The boxes required for filling are taken from above the existing roller table. Full containers are transported from a conventional conveyor onto an inclined conveyor and then shipped for weighing. Next, separation occurs at the metering console. Sorting occurs between large parts belonging to the delicacy group for further salting and massaging, as well as between pieces going for processing. The second category moves to the machine room, where it is crushed using grinders and cutters. Products intended for sale or warehouse storage are also processed accordingly and packaged in individual storage areas.
The meat processing line includes the following equipment for pork cutting:
The equipment for cutting up carcasses also includes a modular belt. It is a set of individual plastic parts produced using a unique high-precision casting method, accompanied by the pressure application and interaction between several axes. This design has reliable strength, increased ability to move loads, and simplified cleaning.
The main conveyor operates with a uni MPB C belt. It has the following technical characteristics:
In turn, the mechanical removal conveyor has a uni S-MPB C class belt, which has the following parameters:
Due to the tight adhesion of the plastic folding belt to the sprockets, lateral movement of the web on the conveyor is not allowed. Modular belts are widely used in many industries. Conveyors (transporters) with modular belts are used in food production and processing industries. The modular belt design allows you to create different configurations of the working surface (cross profile, longitudinal fence, etc.)
The modular belt consists of individual plastic modules made by high-precision injection molding. The surface of the modules can be without or with holes. The actual area of the holes for modular belts designed to cool products or remove water from them can reach 88%.
Sprockets of different sizes are available for modular belts, including collapsible and non-collapsible versions. Sprockets can be manufactured by injection molding or milling.
Sprockets made by casting have holes in their housing, which makes it easy to access all sprockets installed on the shaft during the washing process. Rounded edges and the absence of dead zones eliminate the retention of residual contamination after washing.
The axles connect individual belt modules to each other and provide transverse rigidity of the belt.
A modern deboning conveyor typically has three modular tiers. The first, the main one, is a conveyor used to transport pieces of half-carcasses for further deboning or trimming. The second tier is used for removing bones and sinews or for feeding clean boxes. The third tier is called the container tier and is used for transporting meat boxes. All three tiers are equipped with a modular plastic conveyor belt. Its speed can be adjusted using a frequency converter.
Half carcasses are fed via a system of overhead tracks to the beginning of the line to a vertical cutting table or a receiving table, followed by quartering on a table with a circular saw.
The deboner and trimmer workers are located on both sides of the conveyor at the cutting tables. Their work tables are equipped with removable PE-HD table tops, with holes for discharging cores and trim, 30 mm thick. The processed bone ends up on the upper transport tier, which goes into the bone grinding machine. The line is equipped with a manual or pneumatic mechanism for lifting the conveyor belt for thorough washing at the end of the production cycle. There can also be an integrated automatic cleaning system line. Each meat processing line is designed individually based on the production area and required of the client’s production capacity.
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