Food and Beverage Business
Packaging

Qupaq Denester: Improving Meat-Packing Efficiency With One Line

Qupaq Denester: Improving Meat-Packing Efficiency With One Line denester, efficiency, meat-packing, Qupaq Food and Beverage Business

The Osterfeld meat-packing centre of Kaufland has achieved significant efficiency improvements with the implementation of Qupaq’s tray denesting and product loading technology.

Following the successful integration of a Qupaq solution at its meat-packing center in Möckmühl in 2017, the German hypermarket chain Kaufland decided to invest in a similar setup for its Osterfeld facility earlier this year. The project was completed in August, with the primary aim of enhancing efficiency and reducing maintenance costs through automation. This investment has allowed Kaufland to achieve the same output that previously required two minced meat portioning lines, thus considerably boosting their operational capacity.

Christopher Mader, head of operational services at Kaufland, states, “By implementing the right automation solutions, we can reduce costs and meet a growing challenge in the food industry of limited access to qualified labour. We reached out to Qupaq as we ran into issues with limited space at our meat-packing centre in Osterfeld and wanted to enhance our production efficiency. The system we implemented in Möckmühl did exactly that, and therefore, we chose to invest in a similar solution for our Osterfeld facility.”

The Qupaq solution, while based on standard modules, has been tailored to Kaufland’s specifications. The system features the Anytray CleanLine Denester, supplemented by a buffer and servo stirring mechanism, alongside a loader that fills the trays with both speed and accuracy. This synergy between components creates a fluid, high-performance operation with one line feeding two sealers for maximum capacity.

Christopher Mader notes, “Prior to installing the new Qupaq solution, our setup consisted of two distinct tray denesting and loading systems connected to our meat processing unit. This posed challenges regarding efficiency, coordination, and higher maintenance costs. With Qupaq, we have transitioned to a single cohesive solution that feeds both sealers with approximately 60 portions per minute. The installation has notably enhanced our operations by making it more efficient and cost-effective. The mechanical integration of the packaging line was straightforward and well planned, while feedback from our production team says that operation is simple.”

Consolidating the tray denesting and portion loading has simplified production, leading to significant time savings. This efficiency is evident in the day-to-day operations, with fewer interruptions, a boost in productivity, and expedited turnover times. One of the standout advantages has been the consistent uptime, ensuring that Kaufland’s meat packaging operations run smoothly without unnecessary delays.

Lars Zederkof, CSO at Qupaq, affirms the company’s commitment to creating adaptable solutions aligned with their client’s requirements. He states, “While we offer standard modules, it is vital to establish a streamlined process beforehand to create the best solutions. We pride ourselves on our ability to make adaptable solutions, ensuring they align with our client’s requirements. In Germany, the food industry is working with high capacities, making efficiency a critical factor. We are proud to aid in one of the biggest hypermarket chains in Germany’s transition towards more efficient automation.”

In conclusion, the adoption of Qupaq’s tray denesting and product loading technology has significantly enhanced the efficiency and productivity of Kaufland’s meat-packing centre in Osterfeld. This investment in automation has resulted in streamlined operations, reduced maintenance costs, and increased capacity, contributing to the overall success of the facility.

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