Maximizing Chicken Breast Horizontal Slicer Processing Efficiency: Overcoming Formcook Bottlenecks

We’ve recently received an order from a customer in Spain for a chicken breast horizontal slicer process line. Their request involves slicing Brazilian-origin chicken breasts, which are notably large at 45mm thickness. They require the slicing thickness to be 5mm with a capacity of 1500kg per hour. The customer specifically desires a horizontal slicer machine capable of positioning and slicing four chicken breasts simultaneously in a single line. Additionally, they’ve asked for three machines to be connected to the horizontal slicer, forming a fully automated line: a bin lifter, a bucket loader, and a belt aligner, all preceding the horizontal slicer and a contact form cooker.

Regarding the chicken breast horizontal slicer specifications, they’ve requested a 600mm width belt for a single lane model to fully utilize the width of the oven. They’re interested in a model similar to the Grasselli KSL600. Their process procedure entails slicing, forming cook/contact cooking, and then oven baking. They’ve also provided custom input and output heights to ensure seamless integration with the oven.

The customer must arrange the 4 pieces of chicken breasts in a line because after slicing them horizontally, they need to be processed in the 600mm Formcook (contact cooker). Achieving the desired color takes approximately 45 seconds, creating a bottleneck in our production and restricting the hourly processing capacity. After exiting the Formcook, the chicken breasts are cut using an intelligent dicer, with two breasts grouped per lane. This is the operational flow of the process line.

After consulting with the customer, we performed several tests and ultimately engineered the following components: a bucket loader with a width of 805mm and 4 lines, a belt aligner with a width of 800mm and 4 lines, and a chicken breast horizontal slicer with a belt width of 600mm capable of slicing 4 pieces of chicken breast per line. This processing line boasts an impressive output of 3780 kilograms of chicken breast per hour. Upon passing through the form contact cooker, the output is expected to reach a reliable 1500 kilograms per hour. Additionally, the customer requested that the bin lifter be capable of loading from both the front and right positions. Attached are our design drawings for your review.

Drawing 1

Automated Bin Lifter(Front Position), Bucket Loader, Belt Aligner, and Horizontal Slicer

Drawing 2

Automated Bin Lifter(Right Position), Bucket Loader, Belt Aligner, and Horizontal Slicer

Once all those details were confirmed, we received 100% T/T payment from the customer! Upon receipt of the payment, we promptly initiated the manufacturing process. After 30 days of manufacturing, we successfully completed the production of the machine. Additionally, we purchased two cases of chicken breasts to test the full processing line, capturing photos and videos along the way.

For every chicken breast horizontal slicer order, we ensure precision by running the machine and testing the exact thickness prior to delivery. In the video below, you’ll witness the slicing of 4 lines of chicken breast on a 600mm belt width horizontal slicer, achieving a consistent 5mm thickness for each layer. The slicing process is smooth and even, ensuring optimal results. Upon receiving these videos, our customer expressed delight and satisfaction, describing the outcome as perfect!

Our customer’s chicken breast product contains additional ingredients and undergoes a tumbling process, resulting in a stickier texture compared to natural breast meat. Our primary objectives are to minimize waste and address the issue of stickiness. To tackle these challenges effectively, we have developed a specialized solution: chicken breast horizontal slicer including a water spraying pipe positioned above the upper belt. By integrating this feature, customers can easily connect a water pipe to the spraying mechanism, allowing for the application of water to mitigate the stickiness issue during the slicing process. This thoughtful design not only enhances efficiency but also ensures a higher quality end product, meeting the specific needs of our customer’s production requirements.

After verifying the contact cooker’s input height at 1030mm, we aligned the output height of the belt to match at 1030mm as well, ensuring seamless connection along the production line. Notably, the input and output heights of the horizontal slicer machine are adjustable through footing part adjustments. For a comprehensive understanding, refer to our detailed guide video.

In addition to purchasing the machines, customers often express interest in acquiring additional spare parts. For instance, when considering the chicken breast horizontal slicer, we recommend that customers opt for an additional 30 pieces of blades. Given that each 80-100 ton production cycle necessitates a blade change for the horizontal slicer, this quantity ensures seamless operational continuity. Furthermore, essential accessories include a complete set of upper and lower belts. In anticipation of potential variations in chicken breast specifications, we also include an extra set of guide rails, offering versatility in accommodating diverse product dimensions.

In the European market, obtaining the CE certification is paramount for smooth import processes and customs clearance. We understand the significance of adhering to these standards, which is why all our machines are meticulously crafted using SUS304 materials and are CE certified. This certification underscores our commitment to delivering products of the highest quality and reliability, ensuring that our customers receive machinery that meets stringent European safety and performance standards. Our dedication to excellence extends beyond mere compliance, as we continually strive to exceed expectations and set new benchmarks in the industry.

After-sales issues are particularly important! That’s why we have separately maintenance, installation videos, operation manual book for bucket loader, bin lifter, belt aligner, chicken breast horizontal slicer. So that customers can quickly get started and use them after receiving the goods, saving time and avoiding risks.Below are some of our operation guide videos.

For Bucket Loader

For Belt Aligner

For Horizontal Slicer

After all tests and cleaning procedures are concluded, our chicken breast horizontal slicer process line and accessories will be carefully wrapped with cling film and securely fixed within plywood export packaging boxes. This ensures that the customer receives the goods in pristine condition. Subsequently, we arrange shipping via sea freight to the port of Bilbao in Spain. Throughout the entire process, we maintain constant communication with the customer, keeping them informed at every stage.

Through personalized customization, we can effectively eliminate the production bottleneck associated with double-sided frying equipment, leading to increased efficiency in chicken breast slicing. This not only enhances economic value for our customers but also streamlines operations, reducing labor requirements and paving the way for fully automated production.

In conclusion, our commitment to meeting and exceeding our customer’s needs remains unwavering. From precise horizontal slicing to innovative solutions for stickiness mitigation, and from seamless integration to after-sales support, we strive for excellence at every step. By harnessing cutting-edge technology, adhering to stringent standards, and prioritizing customer satisfaction, we continue to revolutionize the poultry chicken breast slicing industry. Join us on this journey of innovation and reliability as we pave the way for enhanced efficiency and superior quality in chicken breast horizontal slicing production.