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Introducing the Prime CSKB-1 Skinner: a new level of hygiene for poultry processing

Tired of cumbersome poultry skinning systems that have to be dismantled every night to maintain hygiene? Meet the new Prime CSKB-1 Skinner, an ultra-hygenic, simplified solution that combines economy of design with innovations to remove those bacteria traps that have required frequent cleaning in all skinners until now.

Most, if not all skinners, are based around modular belts, which have to be dismantled and sanitized at the close of each day to ensure bacterial build-up does not take place. In contrast, the Prime CSKB-1 Skinner eliminates this problem by replacing the modular design with a seamless, sanitary belt, which can be cleaned by a simple hose down. 

At the same time, Prime Equipment engineers have eliminated many components from the previous skinner design, meaning that many less pieces that could potentially fail or require replacement. With its improved simplicity, Prime estimates a 50% reduction in total MMR cost compared with the previous model (a design which is replicated throughout the industry).

10-minute turnaround
Distilling the advantages, Prime Equipment’s Nick Gasbarro describes the sanitary belt as a step forward for the poultry processing industry. “The simplicity of the machine, which includes getting rid of the paddle wheel and the upper assembly, makes it an easier machine to manage, and this has reduced the Total Cost of Ownership of the Skinner as a whole,” he says.

“To take apart and reassemble the previous version of the Skinner for cleaning was probably a 35-40 minute process for one person and in a lot of plants you have 10-15 skinners; we have now reduced that to 10 minutes.”

When Prime introduced the skinner category, it succeeded in taking people off the processing line. With the new Prime CSKB-1 Skinner, Gasbarro says Prime is reducing the sanitation and maintenance time, which frees up employees to focus on other tasks. 

Revolutionizing skinning
Prime Equipment was started by Nick Gasbarro’s grandfather, Geno, father, Mike, and uncle, Joe, in the early 1990s. Whereas previously skinning chicken and turkey meats had been a labor-intensive task with a poor record on yield, Prime invented a solution that used a “paddle-wheel” shaped roller that automatically removed the skin in a far more effective way without losing valuable meat along the way.

“It was very revolutionary for the chicken industry and really created its own product category,” recalls Gasbarro. “It’s something we are very proud, particularly because it saved a lot of injuries to workers that had previously been common, such as carpal tunnel injuries.”

At this time, the Prime Skinner could be equally applicable to turkey as chicken, white meat and dark, but its initial modular design made it tricky to clean. 

A new level of hygiene
With time, the design of Prime’s original skinner was replicated across the industry, but the cleaning challenge remained, regardless of manufacturer. 

In response, Gasbarro’s grandfather – now in his 90s – has delivered a winning solution once again in the form of a seamless belt featuring flights to replace the wear-and-tear heavy paddle wheel, while at the same time performing the same function. Forming a key component of the new Prime CSKB-1 Skinner, the new belt brings new levels of hygiene to poultry skinning, with cleaning also be carried out by a simple hose down rather than dismantling the entire system.

“The old belts on our skinners and those being used across the industry are modular, so they can be bacteria traps and as a result have to be removed and sanitized at the end of each day,” explains Gasbarro. “With the new CSKB-1 Skinner, the seamless belt eliminates this problem and can be cleaned quickly and simply. Through this action we were also able to eliminate the upper assembly conveyance, which moved the product through the pinch-point, so that means one less moving part that has to be maintained.”

The new Skinner also features a switch from a traditional gear-and-motor drive system to a drum-drive: a single, self-contained motor with a much simpler drive system that lasts longer and uses less energy than the traditional gear motor drive. “We took a concept that was simple and we’ve made it even simpler,” Gasbarro adds.

LEARN MORE about the Prime CSKB-1 Skinner

Meeting the labor challenge: DSI™ solutions for meat and plant-based protein

Protein processors across Europe – and indeed worldwide – have been facing enormous inflationary pressures over the last 12 months, with rising raw material and input costs presenting a major challenge to food companies; one hardly alleviated by consumer expectation of low prices. Faced with such challenges, many processors are being forced to either raise prices or cut costs, but JBT DSI offers a third option that could deliver a solution for many in the industry.

DSI™ Waterjet Portioning Systems provide a proven means of achieving substantial labor savings while at the same time increasing productivity and improving yield, and all with the help of water.

A worldwide success story, DSI Waterjet Portioning Systems are ideal for fast, effective, automated portioning of poultry, meat or seafood, resulting in a superior yield. The system is equally effective in producing portions, nuggets or chunks, fat-free product or strips, and can quickly change applications at the push of a button.

Optimizing profits
How does it work? As each piece of poultry or meat enters the DSI system, it is individually scanned to locate fat and determine shape, thickness, weight, and other attributes. Proprietary DSI Q-LINK™ Portioning Software will then optimize a cut strategy for individual piece of raw product, before computer positioned high-pressure waterjets generate complex cut shapes that make each piece as valuable as possible to maximize profits.

Incredible flexibility
“The huge advantage with DSI is that customers can save having to employ up to 50 persons on a line by installing a Waterjet Portioning System,” explains Niels Buengeler, Area Sales Manager for JBT DSI in Europe. “This is particularly important when many companies across Europe are looking to make labor-savings and more yield by investing in automation.

“The DSI Waterjet System will scan a product as it goes in, calculate the cut pattern, adapt it based on the scan and cut based on that calculation. This is a real superior technology compared to a lot of what has been previously available on the market.” 

Also worth mentioning, he continues, is the incredible flexibility offered by the DSI Waterjet System. Using built-in portioning software, the equipment can produce retail cuts and trim fat at proven belt speeds of up to 30 meters per minute. Typically achieving two percentage point yield increases, the technology is now included in more than 500 installed JBT units.

For those customers keen to try the technology out for themselves, Buengeler adds that tailored tests using DSI™ Waterjet Systems are available at the JBT Food Technology Center for Protein in Helsingborg, Sweden. 

Find out more about DSI™ Waterjet Portioning Systems

JBT’s COOLCAT: putting excessive energy bills on ice

Looking for a re-chiller that performs above the industry standard without sky-high energy bills? The COOLCAT Re-Chiller could be the option you are looking for, thanks to high performance efficiency and a system that builds energy savings into its design.

One of the finest re-chillers available on the market today, the COOLCAT combines superb reliability with one of the most economical systems commercially available; a system which utilizes two hermetically sealed ammonia pumps, one for principal use and the other for back-up in case of unforeseen contingencies. 

Built-in savings
“A lot of savings have been built in to the design,” explains Dustin Huggins, JBT’s Product Manager for Chillers and Re-chillers. 

“The unit is a recirculated system and utilizes a small pump to move the refrigerant vs. hot gas injection. The refrigeration system sees a significant reduction of load with this method. The result is a pretty big savings for any plant that has the Re-Chiller installed.”

Each COOLCAT unit comes with hermetically sealed ammonia pumps for minimum energy consumption, as well as C.A.T.’s unique, patented “U” bends – manufactured using an exclusive proprietary process – which do not leak. 

As well as this, the Re-Chiller includes state-of-the-art PLC control packages as standard on each unit to regulate temperature.

Freeze protection
Using two pumps and the ammonia system, the water going through the piping is cooled to 32℉ (0℃); as close to freezing as you can get without the water solidifying, Huggins explains. However, as an extra level of assurance, the Re-Chiller features built-in freeze protection, and the machine will shut down as a safety measure if the amount of water entering the system reaches too high a pressure. Additionally, it has floating tubes which are not fixed into position which allows both for thermal expansion and gives the tubes room the breathe.

ASME rated at 250psi, each COOLCAT Re-Chiller is tested at C.A.T.’s Russellville, Arkansas factory before being shipped out to customers worldwide. Featuring stainless steel frame and stainless steel components, every model comes completely pre-piped including all refrigerant valves, pre-wired, and pre-insulated, with all necessary isolation valves and pressure gauges included.

LEARN MORE about the JBT COOLCAT Re-Chiller

Keen for a slice of the plant-based protein market? Meet JBT to find out more

Looking to take advantage of the fast-growing market for alternative, plant-based proteins? JBT will have a full range of solutions on show at the forthcoming IFFA 2022 trade exhibition, as well as innovative systems for conventional meat processors, from intelligent cutting machinery to solutions offering connectivity across a production facility.

The market for plant-based protein products is significant and growing. In fact, with a Compound Annual Growth Rate of 9.7%, the market is expected to be worth $23.4 billion by 2028, according to a recent report published by Meticulous Research. 

Save labor and improve yield
JBT solutions ideally suited to both plant-based and meat products alike include the DSI Waterjet Portioning System, which can improve yield, decrease a reliance on manual labor and increase productivity by determining optimum cut strategies using proprietary DSI Q-LINK™ Portioning Software. For the plant-based industry at IFFA 2022 in particular, JBT will be demonstrating how the Waterjet Portioning System’s cutting patterns are ideal for the consistent portioning of products such as tofu. 

Other featured solutions include the Formcook Contact Cooker, an innovative method for sealing moisture into protein products which is perfect for healthy cooking. Using teflon belts, the Formcook Contact Cooker can improve both yield and flavor, while delivering a healthier cooking experience, thanks to a minimum need for oil. 

Further down the production line – and as applicable for meat as it is for plant-based protein – is the Frigoscandia GYRoCOMPACT® 70 Spiral Freezer, an innovative, self-stacking freezing system, which delivers advances in food safety, performance and space optimization. Already being successfully used by customers like Marlow Foods (the company which gave the world Quorn), the Spiral Freezer provides quality, food safety, reliability and operating simplicity at its core.

Proven solutions
In addition much of JBT’s family of companies will be showcasing winning solutions for protein processors at IFFA. Tray sealing specialist Proseal will be highlighting its leading role in fast, efficient and high-quality meat and poultry packing, including the proven GT2e tray sealing machine and recently launched CP3™ case packer.

High Pressure Processing (HPP) solutions provider Avure will be showcasing its end-to-end systems that deliver a more natural appearance and are capable of doubling, tripling, or even quadrupling a meat or plant-based product’s shelf life. For meat processors of all sizes, TIPPER TIE will be displaying a full range of automated and semi-automated clipping solutions, while Schröder will be highlighting its favorably-priced injector systems for companies large and small.

Unrivalled connectivity
A key area being highlighted by JBT at IFFA 2022 is connectivity, and the ability of JBT to provide customers with instant access to joined-up, up-to-the minute performance data. The newly-launched JBT OmniBlu platform – a subscription-based service including best-in-class support, parts availability, and machine optimization capabilities – features a powerful digital backbone leveraging AI, machine learning, and predictive analytics.

The OmniBlu solution enables customers to have a complete picture of the current performance of all equipment, enabling them to achieve optimum product results and tackle any potential problems. Learn more about OmniBlu HERE.

JBT will be exhibiting at IFFA 2022 in Hall 8.0, Stands J90 & K90 at Messe Frankfurt in Frankfurt am Main, Germany from May 14 – 19, 2022.

Book a meeting at IFFA and find out how you can grow with JBT!

JBT Stein M-Fryer: beat the cooking oil price surge

Soaring cooking oil prices is currently a hot topic for any company involved in mass producing fried foods. Drought-affected harvests and the demand for raw materials from biodiesel plants – combined with Indonesia’s ban on palm oil exports and the war in Ukraine, among other factors – have exacerbated an already difficult situation, meaning pressure on food processors is growing. 

The JBT Stein M-Fryer offers a solution. Using up to 25% less cooking oil in the tank compared with competitor systems, the M-Fryer offers a low consumption solution, which at the same time has been developed to prolong oil quality through gentle heating and sediment removal.

In fact, the M-Fryer will help customers make significant savings on cooking oil, while at the same time generating far less waste by avoiding the all-too-typical production cycle of large volumes of oil having to be thrown away due to spoilage.

No excess oil
“Due to the technology we use in our fryers, the way they are built, and the type of heat exchanger they have, the M-Fryer is able to have up to 25% less oil in the kettle than other competitors,” explains JBT Regional Solutions Manager Marcelo Scharlack.

“Having less oil means a quicker oil turnover and less oil waste. Excess oil will eventually spoil and has to be thrown away. And now the world is suffering a shortage of oil: Indonesia is shutting down palm oil exports, the war in Ukraine is not helping among other reasons, so oil prices are easily in the realm of €4 a litre and beyond. That’s hitting companies hard that use oil for frying.”

Design innovations
A key element of the M-Fryer is its design. A reduced tank volume means a smaller volume of oil is needed to fulfill the job – without prolonging process times. Meanwhile, the design of the heat exchanger, oil circulation, internal filters and sediment removal all serve to keep the oil quality better for a longer period of time. 

“ We keep volumes low and the heat exchanging very gentle,” adds Scharlack. “Having up to 25% less oil will help companies make savings especially as prices for cooking oil are now so high.”

LEARN MORE about the JBT Stein M-Fryer

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