Comprehensive technological solutions for optimizing production in the meat processing industry, and their impact on ethical guidelines and efficiency.
Today, in the meat processing industry, which represents the most important branch of the food sector, in addition to meeting high standards, there is an increasing emphasis on ethical meat production. It is therefore crucial to ensure processes that incorporate and take these aspects into account.
The fundamental directive for ensuring the humane production of meat is Council Regulation (EC) No 1099/20099 on the protection of animals at the time of slaughter or killing, establishes common minimum rules for the protection of animals at the time of slaughter or killing in the Community. In this context, the question arises as to how high ethical standards can be reconciled with the technical challenges of the meat processing industry, while simultaneously achieving an optimal balance between ethics and production efficiency.
For this purpose, animal stunning chambers have become established throughout the industry. Their optimal performance can be achieved by controlling the concentration of gases or optimizing this production process.
Carbon dioxide (CO2) and oxygen (O2) meters are used for monitoring in animal stunning chambers.
Our customer from the meat processing industry encountered the deviation of CO2 and O2 meters in their stunning chambers. This deviation resulted in increased gas and energy consumption, frequent production stoppages, and the occurrence of gas mixtures in the chambers, which negatively affected the final result.
Such deviations not only violated ethical guidelines in animal treatment, but also had a significant impact on the efficiency and profitability of the production line and, in turn, the customer’s business. The not-so-optimal previous situation was therefore not the result of cost-cutting or some kind of “sparing”. On the contrary, the proper arrangement of the line and the establishment of control greatly reduced costs (saving gas and energy by 30%), so that the proper handling of the problem contributes to satisfaction at all levels.
To solve these problems, ELPRO LEPENIK engineers carried out a comprehensive analysis of the existing system and identified key points where deviations occur. With the help of User Approach, a partner program for measurement and control technology and calibration services, we have implemented the following solutions:
To control and monitor the gases in the stunning chambers, we calibrated the system with calibration gases, with an emphasis on accuracy and stability. By introducing different concentrations of CO2 (0%, 30%, 70%, and 100%), we adjusted the operation of the system according to the specific needs of the plant. With this, we have optimized the process on this part.
To increase the accuracy over the entire measurement range of the CO2 and O2 sensors, we implemented and installed IPAQ 4-L INOR measuring transducers. The implementation or installation of measuring transducers made it possible to enter corrections in the entire range – linearization, which the basic system does not allow, as it allows entering corrections only at one point.
We performed a comprehensive service (service) in accordance with the manufacturer’s instructions, which contributed to smooth operation, reduction of outages and related costs.
The solutions we developed for a client in the meat processing industry resulted in the improvement and optimization of the animal stunning process itself.
The customer has seen less congestion, production and other lines are now running smoothly and efficiently. We achieved an increase in the efficiency and capacity of the production line, which contributed to greater productivity and competitiveness in the market.
The solution is energy efficient, as we have achieved a reduction in gas consumption and a direct reduction in costs in this part.
These results not only improved the ethical processing of meat but also raised the performance of the production line and the sustainability aspects of the company.
If you also want to optimize your production process, call us.
An expert in the field of optimization, Rok Samec, is at your disposal for additional information:
Optimal management of gas systems is crucial to achieving high standards of quality and efficiency in the meat processing industry. Our solution has shown that with a precise approach and the use of modern technology, we can overcome the challenges that arise in production processes. This ensures compliance with regulatory requirements while improving plant performance and sustainability.
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For opinions and explanations, they are always available:
optimization expert: Rok Samec
Measurement expert: Zoran Lepenik
Authors: Rok Samec and Mojca Kugler
March 2024
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