A poultry processor has reduced manual handling, improved conveyor hygiene and increased product recovery after addressing inefficiencies on a trim collection conveyor operating in a wet processing environment.
Chicken nuggets and tenders were being transported on a conveyor where excess product accumulated in catch pans beneath the belt. Operators were required to manually transfer approximately 45kg of product each day to the next stage of the process.
Although the product was not being discarded, the recovery process increased labour requirements and operating costs. Workers spent around one hour per day manually transferring product. With labour and overhead costs estimated at $100 per hour, the processor calculated annual costs of approximately $25,000.
The facility also experienced some product loss during the recovery process. At an estimated value of $1.50 per pound, losses were calculated at up to $37,500 per year, bringing the total annual cost of the inefficiency to more than $62,500.
To address the issue, the operations team sought a solution that could improve product recovery, reduce manual handling and streamline production.
Following a site assessment, the facility trialled the FGP C Food Grade Primary Cleaner for Cleated Modular Belts. The system is designed for food processing applications and aims to reduce material carryback and minimise product build up in catch pans.
Available in UHMW and metal detectable versions, the cleaner is designed to meet food industry requirements while helping maintain product flow on the conveyor.
Following installation, operators reported a reduction in the amount of product collected in catch pans, with more material remaining on the conveyor. The cleaner was installed with minimal disruption to existing operations.
After implementation, the facility recorded annual labour savings of approximately $25,000 through reduced manual cleaning and product recovery activities. Based on operational observations, the processor also estimated up to $33,750 in annual savings from improved product recovery, representing a 90 per cent improvement in recovery efficiency.
Combined, these improvements were estimated to deliver annual savings of up to $58,750. Based on documented labour savings alone, the investment achieved a payback period of 22 weeks. When estimated product recovery savings were included, the payback period was calculated at approximately 66 days.
The processor also reported improvements in sanitation procedures, reduced cleaning requirements and lower water usage. These changes allowed staff to focus on other operational tasks while supporting the facility’s efficiency objectives.
The improvements contributed to reduced waste, lower operating costs and enhanced performance across the conveyor system.
