Innovations in the global meat processing industry have shifted from labor-intensive manual processing to increased efficiency through automation in recent years. Many facilities are now processing a greater volume of product and achieving more consistent results. Much of this change has been driven by the need to process product faster, to increase production and to ensure that all facilities, regardless of size, comply with certain levels of hygiene. Products are also expected to meet consistent quality standards and to be able to be processed for longer periods without fatigue. Automatic sausage tying machines are one of the many innovations currently on the market that are designed to improve production for the meat processing industry. The tying of sausages is a time-consuming process that has, in the past, been completed by hand. However, automatic tying machines are now widely used in order to improve efficiency and increase production.
Before we discuss the advantages of the automation of the tying of sausages it is helpful to explain why the tying of sausages by hand is becoming an unviable task in modern industrial environments.
Dependence on skilled labor for the manual linking of sausage products results in higher costs for processing on production lines. This also makes production more sensitive as it is heavily dependant on the availability of the workforce. As humans are limited in terms of speed and ultimately prone to fatigue, it is only natural that production will decrease over time. The links will vary in size and have an uneven surface which can affect how products are presented on the production line as well as how they are packed in packaging materials afterwards. This will also negatively impact the efficiency of packaging.
However, there are significant limitations to manual processing in terms of consistency of quality and of hygiene. The casings are handled by hand, and therefore the risk of contamination, especially when handling fresh meat products, is very high. Moreover, it is impossible to achieve consistent tension when tying casings by hand, resulting in variable links. While some links may look good and have the correct weight, others will not. In terms of industrial quality standards, the biggest challenge is that manual processing does not lend itself to meeting consistent quality standards. This is because human processing is by nature inconsistent and is therefore generally not as accurate as mechanical processing.
Automation is designed to overcome these constraints by implementing sophisticated engineering solutions which are able to operate continuously and reproduce exactly the same results.
High speed tying of sausages by means of an automatic sausage tying machine increases the output of the process enormously compared to tying by hand. An automatic tying machine for sausages ensures constant link length for all products, thus optimum look and ideal packaging are guaranteed. By automatically tying the sausages as much as possible, the contact with the products can be kept to a minimum. Thus, the highest hygiene during the production process is guaranteed, important in today’s food production.
From an economic perspective, the costs of an automation decrease over time. Due to the reduced need for manpower, less is spent on personnel. In addition, less time is lost due to fatigue or changes in staff. Furthermore, an automated system prevents material waste caused by mislaid or broken casings. This results in a higher production volume and optimal material usage. As a result, automation leads to a higher return on investment (ROI) for producers that are interested in a sustainable future.
We assess operational performance indicators as well as business goals to determine the point at which manually linking sausages is no longer optimal and should be replaced by automated linking.
Here are a few key indicators that may suggest that it is time to upgrade. First, if production demand increases significantly and is currently being dealt with manually then consideration needs to be given to automating production. Additionally, if for whatever reason there are currently labor shortages or high staff turnover then production using mechanized systems could be an option. Finally, if there are production inconsistencies that could be occurring by chance such as links that are made to different sizes than others or links that break, then this could be causing problems for your brand and your customers. In these instances reliable automated production would be the way forward.
Investing in automatic sausage tying machines should be preceded by a thorough cost-benefit analysis. Producers must compare the actual costs of the equipment with the savings in terms of labor and materials which will be achieved in the long run. The producers must also analyze the appropriate layout of their facilities to easily integrate the new equipment in their workflows without disrupting production. Maintenance requirements and the training of the personnel operating the equipment must also be analyzed to ensure the proper functioning of the machine over time. Finally, the different levels of automation – from the semi-automatic machines for small productions to fully automatic machines for large productions – must be compared in order to choose the most suitable machine for the production needs of the producer.
Choosing the right model involves matching up the technical details of the model with your specific needs.
For smaller scale producers of sausage, semi-automatic machines can be the ideal machine to produce a moderate amount of sausages while being able to monitor the filling process. Large scale processing plants will benefit more from fully automatic machines, allowing 24/7 operation with minimum presence of personnel. These machines are able to produce a high volume of sausages while maintaining strict control of link length and casing tension even after hours and days of non-stop production.
We analyze several key characteristics of potential machines, characteristics that affect their efficiency and useful life.
Speed and Performance Capabilities
Producers must determine the tying speed in minutes per sausage of the individual models in relation to their own production goals. Additionally, producers must consider whether tying speed can be changed on the machine, and whether the producer can still make different types of sausages or different production runs of the same sausage at the same quality level.
Compatibility with Casing Types
Adaptability is also a key consideration in choosing automatic systems and modern production lines are able to handle a variety of different types of casing, including natural casings, collagen and cellulose casings, and can be set to the correct level of tension in order to achieve the desired results.
Maintenance and Support Availability
After-sales service is critical to the long-term performance of equipment. Having access to replacement parts, technical support and service contracts reduces the risk of downtime and extends the life of the plant by means of regular scheduled maintenance.
LungTai Machinery (Jiaxing) Co., Ltd. of China is one of the major and reliable machinery manufacturers for fully automatic sausage tying machines for worldwide markets. The quality machineries fromLungTai Machinery (Jiaxing) Co., Ltd. are made of high quality materials and can be customized to produce different kinds of sausages with various casings. Their commitment to customers does not stop at the sale of machines. LungTai Machinery (Jiaxing) Co., Ltd. also provides the operators of the machines with the necessary training, technical assistance and prompt maintenance to ensure continued smooth operation of the machines over long periods of time.
Linking, a manual process previously, has become much more efficient, consistent and even more productive for sausage makers, by automating it. They can make even more money from the increased quality of their products and do so in greater volumes, all at a lower cost, as every batch can be tied to exacting standards. This, is especially important for meat processing companies today, as they search for the maximum potential for growth and efficiency in their business, in an increasingly global and competitive market. LungTai Machinery (Jiaxing) Co., Ltd. would be an ideal supplier for the automatic sausage tying machine required.
When deciding whether to upgrade your system, producers should make a decision based on factors such as the potential for growth in production volume, the stability of the workforce, the degree of consistency required between products, the available space for installation within current facilities, and the budget available for an upgrade.
After every use routine cleaning in conjunction with periodic inspections ensures peak performance for extended periods. Most modern bath products are easy to maintain with simple changeable parts that allow minimum down time between servicing intervals.
Yes. Latest designs of stuffing machines are able to stuff sausages with natural, collagen or cellulose casings. The mechanical settings of such machines can be adjusted in order to achieve the optimal tension, which is required for different kinds of sausages, and which is maintained in a uniform way for all of them.
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