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In-line Thigh Meat Deboning

Thigh Filleting System 632

Thigh Deboning Integrated into the Cut-up System

The popularity of boneless, skinless dark meat is rising in many parts of the world and this trend offers poultry processors an opportunity to obtain better margins on their dark meat products. In deboning, two key factors influence profits: throughput and yield. Our Thigh Filleting System 632 is able to process 14,000 legs per hour while keeping the leg in a standard ProFlex Premium Cut-up shackle.

Thigh Filleting System 632

Benefits

  • In-line thigh filleting to avoid rehanging legs/saddles
  • Reduced labour dependence
  • High throughput – 7,000 birds per hour (14,000 legs)
  • Knee cartilage is left on the bone – not in the meat
  • Reducing trimming and maximizing yield
  • Optional skin removal
  • Easy access to machine parts during maintenance and cleaning

Firm Product Positioning Increases the Yield Performance

Through the complete thigh filleting process, the position of the knee joint is critical for precision and yield. The system is designed to securely maintain the knee joint in the same position throughout the entire process thereby optimizing performance and yield.

Knee joint of chicken leg lies precise in thigh filleting system
Chicken leg got knee joint cut open

An Accurate Pre-cut Starts the Filleting Process

After leg processing on the cut-up line, a pre-cut is performed on the front and back of the knee joint before the thigh filleting process. This cut opens up the knee joint for further processing and ensures correct positioning throughout the complete process

Freedom to Process Thigh Fillets With or Without Skin

The deskinning unit effectively pulls off the skin on the thigh meat. It can be set up to bypass products if skin-on thighs are processed. The skin is removed in one piece.

Thigh fillet goes through deskinning process
Chicken meat goes through deboning processHands with glove working with meat
Touchscreen and buttons for thigh filleting monitoring

Save Time and Gain Processing Insights with Easy Production Set-up and Monitoring

The Thigh Filleting System uses a touchscreen to control and monitor the process through a simple and intuitive user interface. Icons, drawings and colour codes are used to guide the operator when navigating on the touchscreen. Each component on the line can be easily be monitored and set up on the touchscreen. Production recipes, consisting of specific configurations of set points throughout the line, can be stored and selected on the touchscreen. Selecting an already configured recipe according to bird characteristics makes set-up fast and easy and ensures production quality and yield performance. During production, the line speed, set points in use, bird throughput and other key production figures can be closely monitored and changed in real time.

Two plates pulling thigh meat from bone

Pulling Process Can Be Adjusted to the Leg Size

The meat-pulling unit uses two shaped plates to pull the thigh meat from the bone leaving it hanging at the hip joint socket. The pulling process can be adjusted to fit the leg size.

Finalizing the Deboning Process with a Perfect Fillet

After meat pulling, the hight adjustable meat-cutting unit releases the thigh fillet while the thigh bone-cutting  unit removes the thigh bone at the knee joint allowing the drumstick to continue on the cut-up system.

Two drumsticks hanging on cutting unit

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Utilize the Whole Bird – Gentle Method of Product Refinement

With the gentle BAADERING technology, various poultry materials can be turned into separate products, while preserving the muscle fibre structure to get the highest quality meat. The end product is low in calcium as well as enzymes, which reduces the pH value for a prolonged shelf life. This technology does not only add value; it also improves sustainability by increasing resource efficiency.

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Minced meat in reel

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