Main Menu
Processing Overview
Partner in Fish Processing
BAADER Products
Primary Processing
Secondary Processing
Flexible Automation in Breast Filleting
Breast Cap Deboner 660A
Tailored for Your Automation Needs
Traditionally, breast filleting has been performed manually on labour-intensive cone lines. However, with increasing processing speeds and the challenge of recruiting and retaining skilled workers, there is a growing need to automate the deboning process. As the poultry industry shifts toward greater automation, it is crucial to these requirements, BAADER offers the flexible Breast Cap Deboner 660A, equipped with customizable configuration options to meet specific automation and processing needs.
Benefits
- Configurable automation level
- Top quality fillet products
- Minimized labour dependence
- Optimized yield performance
- Small machine footprint
- Easy production control and timing adjustments on a touch screen
- Predefined production recipes and easy switch between them
- Great variety of processed fillet products
- Easy access to the processing tools during wash-down
- Transparent protective doors allow for easy monitoring during production
- Saddles can be removed without tools for easy cleaning
Configurable Automation Level
The Breast Cap Deboner 660A is a versatile automatic filleting machine meticulously designed to preserve fillet quality and optimize yield. Its automation can be configured to suit either semi-automatic or fully automatic fillet harvesting, offering the highest degree of production flexibility. The fully automatic version of the Breast Cap Deboner 660A seamlessly handles automatic fillet and tender harvesting, along with keel bone meat and keel bone cartilage (yagen) harvesting. In contrast, the semi-automatic version requires manual fillet harvesting and is not equipped with keel bone meat and keel bone cartilage harvesting tools.
Automatic Fillet Harvesting or Not?
The choice between automatic and manual fillet harvesting depends on several factors. Experienced workers can tailor the process to the unique characteristics of each breast cap, meeting specific quality standards and various market demands. Conversely, automation uses an integrated measuring station to precisely evaluate the size of each cap, allowing real-time adjustments to the deboning tools and enhancing both efficiency and yield. Therefore, the level of automation should be based on the specific needs and preferences of each processor.
Minimum Labour Requirements
Manual deboning is labour-intensive, increasing reliance on human workers and costs. It also introduces uncertainty with worker attendance and production consistency. Maintaining a skilled workforce requires ongoing training, whereas automatic solutions need only basic tasks like loading products. Skilled mechanics are needed for machine maintenance only.
Automation reduces repetitive tasks and enhances workplace safety. The Breast Cap Deboner 660A offers ergonomic, adjustable loading stations for two workers. Caps are securely conveyed through mechanical tools for skinning, scraping, and cutting on rotating saddles, ensuring a seamless processing transition. Easily removable saddles enable quick, hygienic cleaning.
%201.webp)
Minimum Footprint
The Breast Cap Deboner 660A occupies less than nine meters of space on the production floor, allowing for efficient utilization of valuable floor space for other essential purposes.
Gain Flexibility in Production
The Breast Cap Deboner 660A offers a diverse range of fillet products and allows bypassable skinning as well as tender on or off products.
Single fillet, with or without tender attached
Butterfly fillet, with or without tender attached
Tender fillet
Keel bone cartilage (only automatic version)
Fillets can be produced skin on or off.
By-Products
- Breast cap carcass
- Wishbone
- Skin
- Keel bone meat (only automatic version)
- Top membrane (only automatic version)
Leave the Meat on the Fillet
Optimizing yield is crucial, with every gram holding significant value. Thus, the machine features meticulously crafted wishbone knives, designed to preserve more meat on the fillet and minimize meat on the removed wishbone.
Harvest Every Gram of Keelbone Meat
Traditionally, manual deboning relies on the skill of operators to extract meat on the keelbone. However, the fully automatic Breast Cap Deboner 660A excels in efficiently harvesting this residual meat as well as the top membrane.
Tendon Clipping
To achieve the highest quality tender fillets, the Breast Cap Deboner 660A can be upgraded with a tendon clipping module. This enhancement effectively removes any sinew protruding from the fillet, resulting in a more appealing product. Tendon clipping can be performed on separated tender fillets, as well as on single or butterfly fillets with the tender still attached.
Tenders with and without the sinew cut
Easy Process Control
To enhance control and monitoring, the Breast Cap Deboner 660A incorporates a Human-Machine Interface (HMI) control panel located on the plant floor. This user-friendly interface empowers operators to efficiently monitor and adjust deboning process parameters, ensuring optimal performance and yield.
With intuitive navigation and four pre-set recipes available on the screen, production setup becomes fast and simple, especially during production shifts. By utilizing these recipes, operators are allowed to swiftly select the precise machine settings necessary for producing any desired product. These recipes are quick to set up and can easily be modified whenever the need arises. This intuitive feature not only enhances efficiency but also minimizes human errors in machine setup.
Prepared for Data Sharing
Machine data serves as a vital link in the information chain, significantly enhancing the accuracy and efficiency of decision-making. In line with our commitment to empower our customers with insights into plant operations, the deboning machine is designed for seamless integration with the BAADER Edge, enabling secure and reliable communication of machine data.
Automatic Control of Remaining Meat
Traditionally, deboning performance has been monitored using the rest meat scrape test. This method involves manually removing the remaining meat from the carcass, weighing it, and manually recording and reporting the data. It is a time-consuming process and often inconsistent. Additionally, it identifies low deboning performance only after batch processing is complete, delaying corrective actions and resulting in lost revenue.
To provide BAADER customers with an automated tool for continuously and consistently measuring the amount of residual meat left on carcasses, the Breast Cap Deboner 660A can be delivered with ClassifEYE® Rest Meat Detection, an AI-based vision technology positioned after fillet harvesting that immediately shows the amount of remaining meat on the carcass.
Related products
How Can We Help You?
Tell us about your processing requirements and see how our experts can help you improve your quality, throughput and yield.