INNOVA Software solutions that empower poultry processors - Maximize yield and throughput Conform to quality standards and ensure food safety ...
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INNOVA 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 • Optimizes order management from reception to dispatch
• Overview of production data in real time • Plans production capacity and lead time based on raw materials
• Communicates alarms based on device status • Flexibility in responding to changing customer requirements
Get the most out of your investment. Innova enhances the power Processors are pressured to achieve ever-faster delivery times.
of Marel processing equipment, ensuring you the most effective Innova order processing manages and speeds up the complete
processing control available for individual machinery or whole order cycle, including purchase orders, production orders,
processing lines, and provides real-time data for performance inventory orders and sales orders. Moreover, Innova eliminates
monitoring to maximize profitability at each stage. under- and overproduction.
WEIGHING AND LABELING LOGISTICS
• Collects and registers all your weighing data • Complete inventory control from reception to dispatch
• Easy, centralized label management • Real-time overview of inventory status
• Full integration to inventory and/or palletizing • Minimizes handling and transit time
• Reduces loss and expired products
Are you in control of your giveaway? Innova offers advanced
weighing and labeling, fully intergrated with other steps in the Ensuring timely delivery is vital to customers, so it is crucial to have
process. The system fully enables packing, giveaway monitoring the right tools in place to manage all logistical challenges. Innova
and finished goods labeling. 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 • Reduces risk of recalls
the production process • Traceability across the complete value chain
• Reports results of quality specification checks • Incorporates quality assurance registrations
• Supports all major quality systems, such as HACCP, ISO, BRC, IFS • Provides information to fulfill quality certification requirements
Innova ensures that processors integrate dependable quality- Traceability is at the forefront of food safety. The Innova traceability
control inspection in food processing plants. The system allows for engine is built into every process step of the production to ensure
flexible registration and reliable data collection. With Innova, that you can act quickly to minimize the size of recalls. Innova
processors can monitor quality check-points, thereby ensuring makes it possible to trace every product back to its source.
highly consistent quality assurance.
PERFORMANCE MONITORING INTEGRATION SERVICES
• Collects reliable and accurate data • Accesses data across all functions
• On-line information on real-time KPIs • Continuous integration and data transfer between systems
• Dashboards and reports • Standard data interface with ERP and other planning systems
In a processing plant, key performance indicators such as yield, Innova offers standard data interfaces for all your production data.
throughput, quality and efficiency are vital to your business. User-friendly non-stop integration with your other systems
Implementing Innova provides processors with accurate and safeguards processing. Moreover, it ensures that your ERP and
reliable on-line data to help improve performance and make other planning systems can upload and work with data from
intelligent decisions. Innova.
Innova services
Make the most of your investment
We are committed to delivering innovative software solutions that add Our powerful software maintenance program is the backbone of this
value to your business. Therefore we place great emphasis on continuous commitment to our customers. Innova’s service portfolio ranges from
development of products and services that meet your expectations and assistance with routine issues on general software use, to advanced
match ever-evolving trends within the marketplace. consultancy services that empower you to make the most out of your
software investment.
Innova Innova
Software Support 24/7 Support Line
Provides remote and telephone support during normal working Provides access to emergency support for critical incidents
hours. This includes assistance relating to routine questions regarding outside normal working hours and is available 24/7/365.
software use. Information on new or changed configuration and
functionality is provided on request. • Fast response time
• Lower risk of production downtime
• Single point of entry for all Innova service and support • Peace of mind
• Defined service levels, such as response times,
availability and priority rules
• Referral to relevant specialists when required
Innova Innova
Software Maintenance SYSTEM Maintenance
Innova is continuously developed to fit changing market needs Includes a suite of services designed to keep the Innova software and IT
and requirements. Our Software Maintenance Program provides infrastructure in an optimal state. This prevents or minimizes unexpected
users with rights to all new major version releases, service packs downtime and disturbances to overall performance.
and features, which are released on a regular basis.
• System is kept up to date to ensure reliability and availability
• Access to and rights for all upgrades • Costly downtime is reduced through preventive
• A high degree of process and device compliance and protection maintenance to the server, database, network or other
reduces operational uncertainty critical IT infrastructure
• Life cycle support reduces operational risk, improves • Users and operators are evaluated, and training plans
control of IT costs, and reduces financial risk devised, to continually update their competence in
operating and maintaining Innova
Innova Innova
Customer Training Consultancy Services
Designed for IT and technical personnel, operations and production Designed to focus on specific improvement tasks with clear financial
managers, and shop-floor operators, to ensure that users are kept and business goals for customer operations.
up to date on new developments and that their skills to operate the
system are continually improved. • Analyzes future business and financial impact
• Provides better management tools with
• Continuous skills improvements for customer workforce improved KPIs
• Optimized system utilization
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 essential in order to monitor whether or not set goals have been
reached, and to constantly improve efficiency.
Yield has a significant and direct impact on profit, making it one
of the most important KPIs in fresh poultry meat processing. Quality and safety
Given that 65 – 75% of production costs stem from raw materials, Food quality and safety are two of the most pressing issues
poultry processors must maintain complete control of yields and in poultry processing today, reflecting consumer focus and
giveaway at every stage of production. Inaccurate processing, concerns. Retailers demand quality, traceability, longer shelf
checkweighing and/or inexact packing can result in considerable life and no underweight, and suppliers must be able to deliver
losses every day. Even very small fluctuations in giveaway can products that fully comply with agreed specifications. By
result in substantial losses – or substantial profits. keeping the process in line and controlling logistics and manual
Effective control inspection, Marel enables processors to meet all these criteria.
Subject to change without notice / 62110/P107b / Marel hf. / 03.2013
Management information is normally based on historical data Outbound logistics
from previous production runs. By contrast, Innova provides Controlling and tightly managing the outbound logistics
complete access to real-time data on the production process. process from Finished Goods Inventory through Order Picking to
It is then possible to make instant adjustments to equipment Shipment is one of the most critical processes. Meeting customer
settings, orders, throughput, manning levels and other critical expectation on delivery is essential in order to secure customer
factors to optimize production flows, with no need to wait until orders. In today’s world of ever-increasing demands for flexibility,
the next day to make adjustments. small orders and shorter reaction times necessitate further
Throughput reflects efficiency automation and advanced solutions.
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
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 m3 € 30,000
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