Software solutions that empower poultry processors Maximize yield and throughput Conform to quality standards and ensure food safety Achieve full traceability and raise efficiency
Empowering poultry processing With over thirty years of partnerships within the food industry, and a continuous commitment to innovation and software development, Marel has created the unique suite of Innova Software Solutions. Innova combines Marel s production management software and processing know-how to fulfill the individual needs of poultry processors, keeping in step with the industry s ever-changing processing trends. Innova empowers poultry processors to: Control their production Experience real-time monitoring Improve decision-making based on valuable innova insights This enables poultry processors to: Maximize yield and throughput Conform to quality standards and ensure food safety Achieve full traceability and raise efficiency The ultimate objective of Innova is to empower poultry processors to optimize overall production performance and reach their goals. Inbound logistics Primary processing Secondary processing
Bringing it all together The Innova Software Solutions portfolio ranges from simple device control solutions, to total processing solutions adapted to the individual needs of poultry processors. Based on modular designs, the solutions are scalable, thereby providing maximum flexibility for poultry processors, ranging from small operations to large, plant-wide systems. The production management software supports a broad range of Marel processing equipment. This enables processors to optimize overall poultry production, from reception of raw material to dispatch of products. Innova s process know-how empowers poultry processors to deal with daily challenges and optimize results. With Innova, processors can control single devices, or a full range of equipment across the plant floor. Innova production management software can communicate with other systems, such as an existing ERP system, to give you a powerful interconnected management system. It provides a solid foundation for reliable data collection, and ensures full traceability throughout the system. It also allows processors to monitor their key performance indicators (KPIs) such as yield, throughput, quality, capacity and labor efficiency, in real production time. These valuable insights enable processors to identify opportunities for improvements, while ensuring that production conforms to quality and food safety standards. PDS-NT integrates seamlessly with Innova PDS-NT is an intelligent production-control and information system for Stork equipment that focuses on the overhead track shackle process. A modular system covering the entire inline process from live-bird handling to cut-up and deboning, PDS-NT collects relevant product data that is used to maximize product value. PDS-NT works seamlessly with Innova, fully integrating functions such as flock tracking. This integration enables Marel to offer poultry processors with the most extensive production control solution. PDS-NT functionality includes: Integrated flock tracking Live-bird container weighing Camera grading inline weighing Recipe control Fixed-weight batching For further information: www.marel.com/innova Outbound logistics
Optimize your processing power DEVICE AND PROCESS CONTROL ORDER PROCESSING AND PLANNING Optimizes your equipment Overview of production data in real time Communicates alarms based on device status Get the most out of your investment. Innova enhances the power of Marel processing equipment, ensuring you the most effective processing control available for individual machinery or whole processing lines, and provides real-time data for performance monitoring to maximize profitability at each stage. Optimizes order management from reception to dispatch Plans production capacity and lead time based on raw materials Flexibility in responding to changing customer requirements Processors are pressured to achieve ever-faster delivery times. Innova order processing manages and speeds up the complete order cycle, including purchase orders, production orders, inventory orders and sales orders. Moreover, Innova eliminates under- and overproduction. WEIGHING AND LABELING LOGISTICS Collects and registers all your weighing data Easy, centralized label management Full integration to inventory and/or palletizing Are you in control of your giveaway? Innova offers advanced weighing and labeling, fully intergrated with other steps in the process. The system fully enables packing, giveaway monitoring and finished goods labeling. Complete inventory control from reception to dispatch Real-time overview of inventory status Minimizes handling and transit time Reduces loss and expired products Ensuring timely delivery is vital to customers, so it is crucial to have the right tools in place to manage all logistical challenges. Innova provides logistics capabilities that are scalable and reliable, covering all processes from reception of raw materials to proof of delivery. QUALITY CONTROL TRACEABILITY Monitors product characteristics at any stage of the production process Reports results of quality specification checks Supports all major quality systems, such as HACCP, ISO, BRC, IFS Innova ensures that processors integrate dependable qualitycontrol inspection in food processing plants. The system allows for flexible registration and reliable data collection. With Innova, processors can monitor quality check-points, thereby ensuring highly consistent quality assurance. Reduces risk of recalls Traceability across the complete value chain Incorporates quality assurance registrations Provides information to fulfill quality certification requirements Traceability is at the forefront of food safety. The Innova traceability engine is built into every process step of the production to ensure that you can act quickly to minimize the size of recalls. Innova makes it possible to trace every product back to its source. PERFORMANCE MONITORING INTEGRATION SERVICES Collects reliable and accurate data On-line information on real-time KPIs Dashboards and reports In a processing plant, key performance indicators such as yield, throughput, quality and efficiency are vital to your business. Implementing Innova provides processors with accurate and reliable on-line data to help improve performance and make intelligent decisions. Accesses data across all functions Continuous integration and data transfer between systems Standard data interface with ERP and other planning systems Innova offers standard data interfaces for all your production data. User-friendly non-stop integration with your other systems safeguards processing. Moreover, it ensures that your ERP and other planning systems can upload and work with data from Innova.
Innova services Make the most of your investment We are committed to delivering innovative software solutions that add value to your business. Therefore we place great emphasis on continuous development of products and services that meet your expectations and match ever-evolving trends within the marketplace. Our powerful software maintenance program is the backbone of this commitment to our customers. Innova s service portfolio ranges from assistance with routine issues on general software use, to advanced consultancy services that empower you to make the most out of your software investment. SOFTWARE SUPPORT Provides remote and telephone support during normal working hours. This includes assistance relating to routine questions regarding software use. Information on new or changed configuration and functionality is provided on request. Single point of entry for all Innova service and support Defined service levels, such as response times, availability and priority rules Referral to relevant specialists when required 24/7 SUPPORT LINE Provides access to emergency support for critical incidents outside normal working hours and is available 24/7/365. Fast response time Lower risk of production downtime Peace of mind SOFTWARE MAINTENANCE Innova is continuously developed to fit changing market needs and requirements. Our Software Maintenance Program provides users with rights to all new major version releases, service packs and features, which are released on a regular basis. Access to and rights for all upgrades A high degree of process and device compliance and protection reduces operational uncertainty Life cycle support reduces operational risk, improves control of IT costs, and reduces financial risk SYSTEM MAINTENANCE Includes a suite of services designed to keep the Innova software and IT infrastructure in an optimal state. This prevents or minimizes unexpected downtime and disturbances to overall performance. System is kept up to date to ensure reliability and availability Costly downtime is reduced through preventive maintenance to the server, database, network or other critical IT infrastructure Users and operators are evaluated, and training plans devised, to continually update their competence in operating and maintaining Innova CUSTOMER TRAINING Designed for IT and technical personnel, operations and production managers, and shop-floor operators, to ensure that users are kept up to date on new developments and that their skills to operate the system are continually improved. Continuous skills improvements for customer workforce Optimized system utilization CONSULTANCY SERVICES Designed to focus on specific improvement tasks with clear financial and business goals for customer operations. Analyzes future business and financial impact Provides better management tools with improved KPIs
Added value Take the guessing out of processing Poultry processing companies looking for greater efficiency are increasingly focusing on key performance indicators (KPIs) that empower them to gauge how effectively their plant is operating. Yield = competitiveness Yield has a significant and direct impact on profit, making it one of the most important KPIs in fresh poultry meat processing. Given that 65 75% of production costs stem from raw materials, poultry processors must maintain complete control of yields and giveaway at every stage of production. Inaccurate processing, checkweighing and/or inexact packing can result in considerable losses every day. Even very small fluctuations in giveaway can result in substantial losses or substantial profits. Effective control Management information is normally based on historical data from previous production runs. By contrast, Innova provides complete access to real-time data on the production process. It is then possible to make instant adjustments to equipment settings, orders, throughput, manning levels and other critical factors to optimize production flows, with no need to wait until the next day to make adjustments. Throughput reflects efficiency Regardless of the size or scale of their operation, all poultry processors want to make sure that they reap the advantages and financial benefits from the investments they make in advanced equipment. As a result, stringent monitoring of throughput is essential in order to monitor whether or not set goals have been reached, and to constantly improve efficiency. Quality and safety Food quality and safety are two of the most pressing issues in poultry processing today, reflecting consumer focus and concerns. Retailers demand quality, traceability, longer shelf life and no underweight, and suppliers must be able to deliver products that fully comply with agreed specifications. By keeping the process in line and controlling logistics and manual inspection, Marel enables processors to meet all these criteria. Outbound logistics Controlling and tightly managing the outbound logistics process from Finished Goods Inventory through Order Picking to Shipment is one of the most critical processes. Meeting customer expectation on delivery is essential in order to secure customer orders. In today s world of ever-increasing demands for flexibility, small orders and shorter reaction times necessitate further automation and advanced solutions. Subject to change without notice / 62110/P107b / Marel hf. / 03.2013 Close monitoring = financial benefits This example from the poultry industry illustrates the financial benefits of close, continuous monitoring of production yields. Improvement + or per year Euro/year Fillet yield + 0.25% 200,000 kg 600,000 Product loss 0.25% 275,000 kg 425,000 Uptime + 0.5% 20 hours 200,000 Water consumption 5% 25,000 m 3 30,000