GEA Slicing Guide. engineering for a better world

Transcription

1 GEA Slicing Guide engineering for a better world

2 Content ABOUT GEA 3 OUR HERITAGE IN SLICING, LOADING AND PACKAGING 4 AN INTRODUCTION TO SLICING 5 SLICED PRODUCTS 7 PRODUCT PRESENTATION 11 PORTION PRESENTATION CHARACTERISTICS 12 PRINCIPLES OF SLICING 16 PRODUCT PREPARATION 18 OPTIMAL PRODUCT TEMPERATURE 20 CHALLENGES OF SLICING 21 SELECTING THE RIGHT BLADE SHAPE 22 SELECTING THE IDEAL TOOTHING PROFILE 25 BLADE CHARACTERISTICS 26 FLEXIBILITY VERSUS CAPACITY 28 GEA SLICER RANGE 31 GEA LINE COMPETENCE 40 ADDITIONAL EQUIPMENT 42 ADD-ON OPTIONS 45 LOADING DEVICE 47 A-TO-Z OF SLICING TERMINOLOGY

3 ABOUT GEA GEA is one of the largest suppliers of process technology for the food industry and for a wide range of other industries. As an international technology group, the company focuses on world-leading engineering, equipment and components for sophisticated production processes. GEA takes you forward with performance-focused solutions, from single machines to complete production lines for the preparation, marination, processing, slicing and packaging of primarily meat, poultry, fish, seafood, confectionery, lettuce, fresh and frozen vegetables and cheese-based products. Our equipment helps you meet today s operational challenges such as product variety, process flexibility, uptime, reducing the cost per kilogram and per pack, food safety and the environment. From standard plant systems to customized solutions, all GEA food technology is designed to meet optimum hygiene and quality standards, while operating efficiently and sustainably. Our technical expertise is complemented by project management, planning and cost control services to help our customers achieve flexible and cost-effective food production. 3

4 OUR HERITAGE IN SLICING, LOADING AND PACKAGING It all began in 1953, when Herbert Jacobowitz and Otto Koetzsch started a factory in Kempten, Germany that was later became Dixie Union. It started with the first semi-automatic thermoformers in the fifties, slicers in the sixties and packaging materials in the seventies. In particular, the multi-faceted slicer family has proven itself for over 50 years with entrylevel devices, as well as mid-range and high performance solutions for customers worldwide. Milestones include the high-speed Dixie EuroSlicer, Dixie UniSlicer and NovaSlicer, followed by the MegaSlicer. The Evolution packaging machine was a well-established worldwide success because of its uncompromising reliability and safe machine design. After joining Convenience Food Systems (CFS) in 2000, the high-speed, high capacity GigaSlicer slicing machine was introduced - a benchmark in the industry to this date. Vast growth of the Slicers activity led to the commissioning of a brand new, state-of-the art production facility in Kempten in The GEA Group acquired the company in Further developments and technical innovations lead to the introduction of the GEA DualSlicer in Nowadays, GEA offers a complete portfolio of equipment, systems and solutions for the preparation, marination, processing, slicing and packaging through to the handling of the finished packaging. Fully automated production lines with integrated automatic loading continually prove themselves in a variety of applications. In addition to the line solutions, the highly flexible Delta robot-based systems are also part of the loading portfolio. GEA contributes to its customers success with technologies that maximize product utilization, optimize output, enhance product safety with hygienic machine design and increase operational flexibility. By ongoing innovations, GEA continuously pushes back the limits of feasibility. This guide presents an introduction to slicing and loading technology made by GEA. 4

5 AN INTRODUCTION TO SLICING Mechanized food slicing first started around 1900, although the last 60 years have seen the most progress in industrial machines to slice meat and cheese. As the retail food industry moved from specialist butcher s and cheese shops to supermarkets, the emphasis shifted from smaller slicers at the point-of-sale to industrial slicers for pre-packaged portions. GEA s slicers and packaging machines serve this segment, where consumers continually change the way they view, interact with and discard packaging. Five trends can be identified in today's market: 1. Sustainability Awareness of global environmental issues is influencing buying habits accordingly and consumers look for signs on packaging that manufacturers have a green conscience. Sustainability is no longer an optional add-on, it is essential future business planning for the packaging industry. The complete story of a product is important in purchasing decisions - where does it come from, how was it made, what are its recycling credentials? 2. Healthy living The health and wellness sector is a key packaging industry trend, reflecting the public s desire to understand what is and isn't good. Consumer packaging displays health credentials of the product both quickly and concisely allowing consumers to make informed choices. Regulations often stipulate how this information must be displayed, and packaging must balance these needs. 3. Convenience Busy lifestyles mean that consumers look for ease of use and convenient transportation from packaging. Smaller portions (for one- and two-person households), easily disposable, easily opened and reclosable packs are examples. Increased visibility of the product also influences buying decisions. 4. Authenticity There is greater demand for transparency from manufacturers. Origins of products need to be traceable back throughout the supply chain to their source. Advertising on packaging increases credibility and authenticity, and reassures consumers of high quality and honest produce. 5. Cost consciousness People don't want to pay any more than they have to for packaged food, so cost remains a key market trend. Consumers increasingly purchase a product when they are running out of rather than stocking up in a 'pantry-loading' approach. Consequently, smaller and easier-to-carry types of packaging is interesting for money-conscious, last-minute shoppers. 5

6 Our world is changing rapidly Consumer behavior Smaller households require smaller pack sizes, while busier lifestyles pose a need for both convenience and quality. Next to this, environmental footprint is highly monitored and represents a key factor for packaging innovation and development. Retail requirements Retailers and discount supermarkets demand just-in-time delivery of fresh natural and processed products in a very wide range of pack sizes, and suppliers must meet the highest possible standards in terms of quality and product presentation. As a result, manufacturers strive to improve the productivity and adaptability of their production and packaging processes in order to enhance their position in the market. Considerations such as increasing the range of packaging formats and offering a variety of portion sizes are two of the ways they differentiate their products. To help them do this, GEA develops slicing and packaging machines that give manufacturers the flexibility they need. Important parameters here are reducing tooling times (for new packages) and offering more sliced product presentation formats. And because cost is always a key consideration, factors like on-weight portions and low give-away (waste) are drivers in product development. 6

7 SLICED PRODUCTS GEA slicers are primarily used for pork, beef, poultry and cheese. Some of these products have a natural shape like bacon, while others are processed as round, square or rectangular logs or blocks, such as cheese. Below is an overview of the main categories of sliced food products. Pork Cooked ham Cooked ham is made from pork that has been brine cured in a liquid solution of water, nitrite, curing salt and spices. After curing, the still raw meat is placed in a round, oval or angular mold and is heat treated in hot water, steam or hot air. Bacon Bacon is made from pork belly, which has been preserved (cured) in a salt solution or brine. After curing and trimming, the bacon is smoked using wood chippings. Bacon that has been cured and smoked needs to be frozen or refrigerated until eaten. Raw ham The first step for making raw ham is dry curing where the surface is rubbed in with nitrite curing salt (further spices and herbs can be added to the salt). After salting, the ham is left to rest for a few weeks in climatic rooms. The conditions set in the climatic rooms determine how mature, firm and dry the ham is to be. 7

8 Cooked sausage Cooked sausages such as mortadela are produced from blanched or pre-cooded meat. Besides meat and back fat, certain other meat raw materials such as liver, tongue and blood can be used. The pre-cooked material is ground, salted and spiced and cooked again after being put into natural or artificial sausage skins. Beef Raw beef The raw beef typically used for carpaccio is beef sirloin. It is partially frozen before slicing to allow very thin slices. Dried beef Dried beef such as bresaola is air dried, salted beef that has been aged over two or three months until it becomes hard and its colour turns dark red, almost purple. It is made from the cow's rear leg, lean and tender, with a sweet, musty smell. Dry / fermented sausage Dry / fermented sausage is a cured sausage, consisting of fermented and air-dried meat, typically beef or pork. Countries and regions across Europe make their own traditional varieties. 8

9 Poultry Cooked poultry ham (turkey bacon) Made from poultry that has been processed in a liquid solution (water, nitrite curing salt and spice). After this so-called curing, the still raw meat is placed in a round, oval or angular mold and is heat-treated in hot water, steam or hot air. Cheese Rigid natural cheese Examples of rigid natural cheese include Swiss cheese like Gruyère, as well as Old Amsterdam, Leerdammer, etc. To produce natural cheese, milk is heated slightly before lactic-acid producing bacteria and rennet are added. The milk coagulates into a single huge curd, which is subsequently heated to remove whey. The curd can then be molded and shaped into a cheese. Salting takes place, and the cheese is matured in a cool, well-ventilated space.. Processed cheese Processed cheese typically comprises two or three cheese types blended together. It is made from unfermented dairy ingredients, plus emulsifiers, extra salt, and food colorings. It does not develop the characteristic flavor of natural cheese because the micro-organisms that create the individual taste are effectively killed off. 9

10 Fish & Vegetarian products Fish Fish is very sensitive to temperature and it needs to be sliced at quite a low temperature of around -8 to -7 C. It is even easier to slice with frozen crust on the surface. Vegetarian aspic Ingredients such as vegetables are set into a gelatin mix made without stock or consommé. Sliceable aspic is made in an aspic mold. To slice such a demanding product, a frozen crust surface is indispensable. Processed tofu Tofu is made by coagulating soy milk and then pressing the resulting curds into soft white blocks. Apart from fresh tofu, there are many different processed varieties, such as picked, dried, frozen etc. in or to match the textures and flavors to the likes of cheese, eggs, bacon, etc. 10

11 PRODUCT PRESENTATION The appearance of a product in the package contributes to consumer buying decisions. So the more attractive and appetizing a product is, the more it stands out on crowded supermarket shelves. GEA slicers arrange sliced products in a variety of visually appealing, space-saving and consumer-friendly ways. Portion presentation forms in the package The way sliced products are presented and packaged have visual and functional characteristics. For example, presentations like shingles allow consumers to see more of what they are buying. Shingled products can be arranged in various configurations, such as circular, oval and linear. Interleaved products have a paper sheet between each slice to make it easier to take one slice from the stack, and this is particularly useful with very thin slices or products that tend to stick together. The examples on the next page show what is possible. The more basic formats, like folded ham can be made on every slicer whereas some of the more complex forms require options to be specified and fitted. 11

12 PORTION PRESENTATION CHARACTERISTICS Shingle The shingle provides the most extensive presentation of a product and gives optimum separation of the slices. It is a consumer-oriented presentation suitable for all kinds of products. Stack The stack is the most space-saving packaging format for efficient use of the space on the supermarket shelves or cooling cabinets. It is a low value-oriented presentation and is well suited for bulk packaging. 12

13 Zig Zag The zig-zag variation of the stack enables easy separation of the slices without an interleaved paper sheet. It saves the initial investment for an interleaver and reduces the amounts of consumable material required. It is a medium value-oriented presentation for slightly sticky products. Interleaved Interleave provides safe and easy separation of slices, and is typically used for high quality and/or sticky products. It is a premium value-oriented presentation for products. The interleaved sheets are inserted between each slice during the slicing process. 13

14 Shaved A shaved presentation helps create high-volume portions. It is a presentation that reveals the product s aroma to its fullest as well as making it easier to take a single slice from the portion. Chunks Chunks are the basic format for single thick slices or pieces. It is a common portion form in the bacon and cheese industry.

15 Folded The folded portion form is an appealing and distinctive presentation to draw the customer's attention and arouse his appetite, and make the product stand out on the supermarket's cooling display. Specials Special portion forms include custom configurations such as meander, oval and trendy or seasonal / themed (such as Chistmas trees). Additional equipment is needed for these particular portion forms. 15

16 PRINCIPLES OF SLICING The process is basically similar on most slicing machines, although it depends to some degree on the application and machine set-up. The product either a processed log with a consistent cross-sectional area and density or a natural cut like bacon is fed at a very controlled speed into a cutting area where a rotating blade produces slices. These are fed in portions into a packaging machine, so slicing intermittently stops after a preset number of slices to separate each portion. The thickness and number of slices determine the portion weight, so in order to make consistent portions of the same weight, it may be necessary to vary the thickness of one or more of the slices. Working principle (4 steps) 1. A product in single or multiple lanes (side-by-side or with a determined space in-between) is fed into the slicer, either via an infeed conveyor for automatic loading solutions or directly on the product bed of the slicer for manual loading solutions. 2. Product grippers grip the rear end to clamp and stabilize the product during slicing, which is especially important for the last few portions. For safety and loading reasons, a shutter is positioned in front of the blade, which swivels down to allow the product to enter the slicing area. 3. The grippers move the products towards the slicing area, in which a blade (either a circular or an involute blade) is rotating. The blade slices the product and the portions are arranged on the portioning conveyor. 4. By movements of the belts the finished portion is transported to the next aggregate in the line until it is loaded into the packaging machine. Working principle (simplified) 16

17 Indicators Results in slicing are influenced by several factors. The two main aspects on which slicing results depend are technical aspects and the product. From a technical point of view, the blade, machine parameter setup, and machine configuration can influence the slicing result. Product related factors include the consistency of the product, temperature during slicing and the calibration. Let us have a closer look at the product related factors first. 17

18 PRODUCT PREPARATION To slice products perfectly, it is not only necessary that the mechanical set-up of the slicer is correct, the preparation of the products is also very important. The consistency of the product determines the preparation for cutting. In addition to setting up the machine regarding pressure on the product and length of the logs for example, it is important to have the product at the right temperature. This can be achieved using a cooler, or for even lower temperatures, a freezer. Cooling a soft sausage (boiled sausage), makes the product relatively stiff, which enables better slicing. 18

19 Meat preparation Core temperature of the sausage should be less than 2 to 3 C above the crystallization point of the product. The crystallization point can be lower than 0 C as it depends on the product character (salinity). Core temperature should always be the same or higher than the surface temperature. Surface temperature can sometimes be lower than the temperature of crystallization point. Lower surface temperature will mostly be achieved with shock freezing, which only cools the surface, to get required stiffness. It may be necessary to slice the sausage warm, for example dry salami, although meat should not be sliced above +4 C, in order to avoid bacterial problems. Cheese preparation The temperature of cheese for slicing is not as critical as for meat products. The temperature is typically around 4 C. 19

20 OPTIMAL PRODUCT TEMPERATURE The product is too warm: irregular, wavy slices irregular portions visible product shavings product tends to get a cutting-beard product may be pulled off from the gripper fatty traces on the slicer blades for products with hard ingredients, some pieces will pull off during slicing The product is too cold: Slices roll in easily (chips effect) Slices are unstable during transportation Within the portion, slices do not adhere (ice on ice), so proper portioning is virtually impossible portioning of the slices is not possible portions will not stay together as they transport over the gaps between conveyor belts Products Core temperature ( C) Surface temperature ( C) Smoked Bacon Bacon Cooked Ham Cooked Sausage Salami Meat (i.e. Carpaccio) Aspic Natural cheese Light Cheese Soft Cheese Fish (pressed) Black Forest Ham Parma Ham to 10 0 to 10 4 to Based on averages. Our GEA specialists can advise you on your specific application. 20

21 CHALLENGES OF SLICING During slicing, the blade heats up and the cutting edge can reach temperatures over 120 C. Protein in the product will coagulate at approx. 73 C. Because of this, a sticky crust will adhere to the blade's cutting edge, thus affecting the slicing result negatively (particularly with dry, protein containing products such as cheese). As brief contact as possible between the blade and the product minimizes temperature, and special coatings such as Teflon help to minimize adhesion of protein to the blade. Meat Slicing meat or sausage requires a sharp cutting edge otherwise the product will be wrenched out microscopically. If the cutting edge of the blade is no longer sharp, the structure of the product will be damaged and the slice quality will decrease. The guiding of the product is also essential for perfect slicing results. These can be achieved by shear edges, which are perfectly adapted to the product. Cheese For cheese products, a sharp cutting edge is also required. But since cheese contains a high percentage of protein which tends to stick to the cutting edge, fully coated blades are a necessity. The blade s coating does reduce the sharpness of the knife. How to overcome these challenges? Distance adjustment For perfect slicing results, it is important to optimally adjust the distance to the cutting bar. If the distance is too big, the product cannot be sliced properly. To increase the product's stability in the slicing process, a downholder system is used. Downholders are mainly used in circular blade applications. For higher speeds and involute blades, product stability during slicing can only be achieved by using a traction belt system. 21

22 SELECTING THE RIGHT BLADE SHAPE The blade is an integral part of the slicer. Using the right blade for a particular application helps to achieve outstanding accuracy per slice, optimum line performance and the most attractive appearance of the sliced portion within the pack. Two different types of blades are typically used: circular and involute blade. And both blade types are available with or without coatings, all for a variety of applications. Circular blade GEA circular blades are available with diameters of 420, 440, 460 and 480 mm Universally applicable for a huge range of products Product preparation is less intensive than for slicing with involute blades Slicing speed up to a maximum of 750 rpm Blade movement during slicing Circular blade slicers include a rotor with planetary movement. With every rotation, the circular blade rotates seven times on its own. Thus, a high draw is generated, allowing the product to be sliced in the centre and in the lowest position (low overlap). With a transmission ratio of 1:7, the maximum speed for circular blade slicers is 600 rpm. A maximum speed of 750 rpm is feasible if the transmission ratio is adjusted to e.g. 1:5.6, however, the draw ratio will start to decrease. Circular blades are very convenient for slicing up to 400 rpm, without a need for idle cuts. Temperature regulation is not as critical as with involute ones, which is another advantage. 22

23 Involute blade Involute blade with different radius High slicing speeds of up to 1500 rpm are possible Works in combination with GEA s idle cut technology to prevent slivers, etc. Bigger products can be sliced as involute blades cover a bigger slicing throat Slicing and portioning is more challenging than with circular blades Products require more preparation (welltempered product) Blade movement during slicing With involute blades, the product is sliced by two movements: slicing and pulling. Because of the pulling movement through the product and the logarithmic geometry, the draw ratio is lower but constant. Due to the rotor s simple construction, it is possible to slice up to 1500 rpm. But as the draw ratio is much smaller compared to circular blades, more pressure is being put on to the product. Therefore, an involute blade must exactly suit each application to achieve optimal slicing results. Slicing with involute blades is more complex and is commonly used for high speed applications of more than 600 rpm. Such high speeds require an idle cut rotor to ensure perfect slicing and portioning quality and to allow sufficient time to transport the portion out of the slicing area into the next aggregate, before slicing the next portion. 23

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25 SELECTING THE IDEAL TOOTHING PROFILE Toothed blades minimize compression of the product. These types of blades are also used in interleaver applications, to slice both product and paper leaves simultaneously. Peak toothed, coated blade With these type of blades, the cutting pressure is reduced. Portioning is constant and in good shape. The cutting, however, is similar to a rasp, creating cutting dust. Toothed blades are commonly used in the cheese industry only. Curve toothed (arch toothed), coated blade Cutting pressure will decrease even further when a curve toothed blade is used. With cheese, it will lead to noticeably better results in portioning and quality. Cutting dust is reduced by 50% on average compared to peaked toothed blades. Curved toothed, coated blades also reduce the consumption of power by the rotor drive. This toothing type is also used in the sausage industry for cooked ham and cooked sausage. Mixed toothed, coated blade Mixed toothed, coated blades are used in interleaver applications. Whereas the arched teeth slice the product, the peak teeth typically slice the interleaver foil or paper.

26 BLADE CHARACTERISTICS Various coated and uncoated blade types are available for a variety of applications. While fully coated blades are mainly used in the cheese industry, uncoated blades are basically used in meat slicing applications. The protein in meat would destroy the blade's coating and lead to corrosion of the blade's edges. Consequently, the edge is mostly uncoated in the meat industry because a very sharp blade is needed in these applications. Uncoated blade: hard-chrome plate Main advantage of a hard-chrome plated blade type is that the cutting edge is very hard, because no coating was applied in the manufacture of this blade. Hard-chrome plates are not indicated for slicing products with a high percentage of protein, as this would stick to the blade and leave fatty sediments to the sliced product. These blades are mainly used for slicing hard products such as smoked ham, salami or fresh meat, that require a sharp and stiff cutting edge. Teflon coated blade Blades can be coated to reduce friction, to improve and prolong durability and to protect against corrosion. Coated blades with a grinded cutting edge a so-called blank cutting edge - can be used for cooked ham, sausage and aspic. This blade is fully coated. Its main advantage is that protein will not clog easily, and fatty traces to both blade and product is reduced considerably. 26

27 Stainless steel, uncoated blades GEA's newest blade generation made of high quality stainless steel with a hard metal knife edge provides convincing slicing results. The balancing process for involute blades has been optimized. The result: no need to adhere additional counter weights onto the surface, thus assuring highest hygiene standards and lowering noise emission. Because of the material's properties, less grinding is needed. The manufacturing process ensures high stiffness of the blade, resulting in consistent slices. Grinding of blades All GEA blades can be sharpened. However, blades with a full Teflon coating need to be re-coated. GEA blades can be sharpened to a maximum of 5 mm less than the original radius. If more millimetres would be taken off, the weight of the blade will no longer match with the rotor and its counter weight. In time, the rotor will be damaged! Coated blades in the future GEA continuously strives to improve coating solutions that will prolong the blade s lifetime, razor sharp cutting edges and first-in-class anti-adhesion features. 27

28 FLEXIBILITY VERSUS CAPACITY Sliced meat and cheese manufacturers need to be flexible in terms of the types of products made and variations in presentation and packaging without compromising on overall line performance. GEA can advise on how to meet this challenge. The priority is to get the best out of products in terms of yield, slice quality and presentation. To do this, it is necessary to establish whether a limited number of product types will be sliced in very high volumes or many different products are to be sliced in smaller batches on a more flexible line. These criteria influence the choice of equipment. Slicing within the target weight to boost yield Yield is influenced by many factors, including slicing within the target weight, increasing the percentage of on-weight-portions and reducing debris and end pieces to a minimum. GEA covers these requirements by using innovative scanning systems and blade technology as well as implementing individually designed grippers and shear edges. Analyzing irregular and natural products The GEA OptiScan is a pre-scanner that uses X-ray technology to determine variations in density along the length of a product and then calculate the thickness of each slice and size of each portion prior to slicing. This ensures the portions are within the target weight and is particularly important for slicing natural products like bacon and cheese with large holes where the variation in density and weight is high. After slicing, the portions are weighed on a dynamic scale, GEA Check 4000, and any deviation from the expected weight is fed back to the control system to make adjustments for the next portion. Smart software is integral to optimizing yield. Idle-cut technology Blade technology plays an important role in reducing debris. GEA employs its unique idle-cut technology that moves the blade away from the product between cutting portions to reduce slivers, while the shear-edges are designed to prevent movement of the product and it is fed into the slicer. Using the right blade profile is also critical for reducing waste like slicing dust. 28

29 Application-specific options Reducing the size of end pieces, which is typically around 20 mm, is best done by using applicationspecific grippers for each product type. An application-specific gripper can reduce the end piece to 15 to 18 mm, and by ensuring the grippers are quick and easy to change over, the machine s overall uptime is optimized. If a very high capacity line is needed, the GEA GigaSlicer that handles up to six lanes of salami for example, would be the best choice. However, if flexibility is more important, the two-lane GEA DualSlicer is ideal. GEA lines can satisfy both flexibility and capacity requirements. A full product overview is given in the following section. 29

30 GEA SLICER RANGE 30

31 GEA SLICER RANGE The GEA slicer range offers cutting-edge technology for innovative slicing applications. Developed to meet tough hygiene and safety standards, each GEA slicer provides unsurpassed performance and outstanding costsaving benefits. Our portfolio also includes smart loading solutions for fully automated, hands-free production. Your performance benefits High performance, due to GEA's application and process know-how over decades Flexible production, thanks to easy calibration Reduced give-away Easy handling and cleaning throughout the entire product portfolio, with minimal downtime Full service and spare parts support Reliable quality, long equipment lifetime Line compatibility: GEA Slicers can be easily integrated into fully automated packaging lines. Flexibility Design your requirements in consultation with us, and GEA will configure the optimal slicer for you. The best of all: our equipment is flexible so you do not need to determine a single configuration for its entire life. With the modular construction of the GEA Slicing range, you can build a machine which is uncompromisingly tailored to your applications of today - and still remain open to the demands of tomorrow. 31

32 Technical data GEA UniSlicer GEA UniSlicer S GEA UniSlicer L GEA UniSlicer Contour Type of blade circular blade circular blade circular blade Blade sizes Ø 420 mm Ø 420 mm Ø 420 mm Max. cutting cross-section 135 x 220 mm 154 x 240 mm 154 x 200 mm Machine dimensions L / L1 x H x W - / x x 856 mm / x x 856 mm / x x 856 mm Max. blade speed 600 1/min /min /min. Max. product length 980 mm 980 mm 980 mm Product loading manual manual manual Check weigher - i i Portioning conveyor I transfer conveyor as i - portioning conveyor Contour portioning conveyor - - I Power supply (max.): 7kW; compressed air: 6 bar; Noise emission in accordance with EN ISO 11204: 71.5 db (A); Depending on product and application I available as standard i optionally available Examples of applications 1x 150 mm 3x Ø 80 mm 2x 100 x 100 mm 1x bacon / dry-cured ham (70 x 220 mm) Outfeed height Uni S ca mm Outfeed height Uni L ca. 960 mm H L L1 32

33 GEA UniSlicer The GEA UniSlicer with circular blade technology increases operational flexibility in two ways: it slices a wide variety of products and produces a range of portion patterns. This slicing machine achieves up to 600 rpm and has a wide product throat, thus combining high throughput with a virtually small footprint. Its compact design makes the GEA UniSlicer easy to integrate into existing production lines. The machine can be specified for operation from either side according to the plant layout. Performance at a glance Attractive product presentation: the GEA UniSlicer slices all portion patterns commonly employed in the market for sausage, dry-cured and cooked ham, bacon and cheese at a high level of quality. Programs for selection of portion patterns. Flexibility with regard to portion patterns: functions like contour shingle conveyor and the folding device mean the GEA UniSlicer can handle a very broad range of portion patterns. Fast and easy change-over from one product to another: manual product loading, changing of grippers and new program selection enhance productivity of smaller batch sizes. Maximum product utilization: dynamic high-performance weighing equipment and the variable portion sequence optimize product utilization on the GEA UniSlicer. The GEA UniSlicer has an output of up to 450 kg/h. 1 1: depending on product and apllication 33

34 Technical data GEA MegaSlicer GEA MegaSlicer S GEA MegaSlicer L GEA MegaSlicer XXL Type of blade circular blade circular blade involute blade Blade sizes Ø 440; Ø 460; Ø 440; Ø 460; R 415 mm Ø 480 mm Ø 480 mm Max. cutting cross-section 350 x 155 mm 440 x 155 mm 440 x 180 mm Machine dimensions L x H x W product length x x mm x x mm x x mm Machine dimensions L x H x W product length x x mm x x mm Max. blade speed 600 rpm (750 rpm) * 600 rpm (750 rpm) * rpm Max. product length mm / mm / mm 1 Product loading manual automatic automatic Interleaver i up to 3 lanes i up to 3 lanes i up to 3 lanes Contour portioning conveyor i i i Check weigher i i i Camera i i i GEA OptiScan - i i Telemonitoring / Remote Service / Preventive Maintenance i GEA UptiFox i GEA UptiFox i GEA UptiFox Power supply (max.): 15.5 kw; compressed air: 6 bar; Noise emission in accordance with EN ISO 11204: 65.6 db (A) 1 Depends on machine configuration and product features. *Depends on product-special machine execution i optionally available Examples of applications MegaSlicer S MegaSlicer L MegaSlicer XXL 3x 100 x 100 mm 3x 100 x 100 mm 3x 150 x 100 mm (upright) 3x Ø 110 mm 4x Ø 100 mm 4x Ø 110 mm 2x Ø 135 mm 3x Ø 135 mm 3x Ø 135mm 1x bacon / dry-cured ham (100 x 220 mm) 2x bacon / dry-cured ham (100 x 200 mm) 2x bacon / dry-cured ham (100 x 220 mm) GEA MegaSlicer L / XXL (product length 1200) GEA MegaSlicer S 34

35 GEA MegaSlicer When it comes to high productivity and covering a very wide range of applications, the GEA MegaSlicer offers one of the most efficient combinations available in the market. The choice between circular or involute blade technologies allows the machine to be used for a wide variety of applications and capacities. Equipped with involute technology, the GEA MegaSlicer can achieve slicing speeds up to 1500 rpm. Thanks to short, automated loading times and high output, the GEA MegaSlicer is ideal for integration into fully automated lines, e.g. in combination with a GEA ShingleLoader and a GEA PowerPak. Performance at a glance Attractive product presentation: the GEA MegaSlicer slices all portion patterns commonly employed in the market for sausage, dry-cured and boiled ham, bacon and cheese at a high quality level. Constant portion quality: the patented idle cut rotor enables constant slice thickness, even with soft products such as boiled sausage, and largely eliminates sliver slices. Choose your blade technology: involute blades for high output with slicing speed up to 1500 rpm; circular blades for flexibility and a wide range of applications. Automatic loading from the rear: fast, reliable and protects the product. Flexibility thanks to many auxiliary modules: functions like interleaver and a contour shingle conveyor make the GEA MegaSlicer a specialist in every product segment. Maximum product utilization: supportive technology such as a dynamic weighing system, a camera unit or the GEA OptiScan secure minimal give away and a very high proportion of onweight portions. The GEA MegaSlicer has an an output of up to kg/h. 1 1: depending on product and apllication 35

36 Technical data GEA DualSlicer Type of blade involute blade Blade size R470 Max. cutting cross-section 500 x 200 mm Machine dimensions L x H x W x x mm Max. blade speed rpm Max. product length mm Product loading automatic Interleaver i up to 2 lanes Contour portioning conveyor i Folding device i Check weigher i Independent drives max. 2 GEA OptiScan i Telemonitoring / RemoteService / Preventive i GEA UptiFox Maintenance Depends on machine configuration and product features. Power supply (max): 15.5 kw; Compressed air in accordance wih 7:4:4-ISO8573-1: 6 bar 15NI/min. Cooling water necesssary; Noise emission in accordance with EN ISO 11204: 73 db (A) i optionally available Examples of applications 2x 230 x 100 mm 4x Ø 110 mm 2x 110 x 165 mm 2x D-shaped ham (180 x 140 mm) 2x cooked ham (240 x 135 mm) 36

37 GEA DualSlicer The GEA DualSlicer meets very high performance requirements. Benefits include maximum output, with fewer idle cuts, thanks to two independent drives and an adjustable rotor head in combination with the 3-stage-portioning conveyor. The independent drives lead to very low give-away, high product utilization and a high percentage of on-weight portions. The adjustable rotor head ensures optimal positioning of rotor and blade towards the product to achieve optimal results. The GEA DualSlicer is ideal for integration into fully automated lines, e.g. in combination with a GEA ShingleLoader and a GEA PowerPak. Performance at a glance Low give away and maximum output: thanks to two independent drives and a 3-stage portioning conveyor. Smooth slicing, fewer idle cuts and perfect portioning results: due to rotor head design, GEA Idle Cut Technology and dynamic cutting gap setting. Easy to operate: machine is set up quickly, with automated control of product specific blade positioning (touch screen). Reduced loading times thanks to automatic loading. Flexibility thanks to many auxiliary modules: functions like interleaver and a contour shingle conveyor make the GEA DualSlicer a specialist in every product segment. Maximum product utilization: supportive technology such as a dynamic weighing system, a camera or the GEA OptiScan secure both minimal give away and a very high proportion of on-weight portions. The GEA DualSlicer has an output of up to kg/h. 1 1: depending on product and apllication 37

38 Technical data GEA GigaSlicer Type of blade involute blade Blade size R 550 mm Max. cutting cross-section 640 x 210 mm Machine dimensions L x H x W x x mm Max. blade speed rpm Max. product length / mm * Product loading automatic Folding device i Check weigher i Independent drives max. 4 GEA OptiScan i Telemonitoring / Remote Service / Preventive Maintenance i GEA UptiFox Depends on machine configuration and product features. Power supply (max.): 16 kw; compressed air in accordance with 7:4:4-ISO8573-1: 6 bar 40NI/min. cooling water necessary; Noise emission in accordance with EN ISO 11204: 76.0 db (A). *Option. i optionally available Examples of applications Up to 6 x 105 mm slicing area Up to 4 x 110 mm x 150 mm slicing area Up to mm x 165 mm logs Up to 4 x 135 mm slicing area Up to 4 x D-shaped ham 38

39 GEA GigaSlicer The GEA GigaSlicer is the highest capacity solution within the GEA portfolio. Its large cross-section of the cutting throat (640 x 210 mm) enables cutting of up to six sausage logs with a diameter of 105 mm, or four cheese logs measuring 110 x 165 mm. Functions like motorized adjustment of the blade position in relation to the product and automatic cutting gap setting guarantee constant uniform portioning. The patented idle cut rotor system contributes to consistent slice quality and largely eliminates sliver slices. Performance at a glance High-quality product presentation: the GEA GigaSlicer slices all portion patterns commonly employed in the market for sausage, dry-cured and cooked ham as well as bacon and cheese at a consistent, high quality level. Constant portion quality: automated adjustment of blade positioning, dynamic cutting gap setting as well as the patented idle cut rotor enable constant slice thicknesses, even with soft products like boiled sausage, and largely eliminates sliver slices. High degree of product safety: due to easy accessibility and hygienic design. Maximum product utilization: depending on the product requirements, the most suitable technology can be selected - with the dynamic weighing system or the GEA OptiScan, to ensure minimal give away and a very high proportion of on-weight portions. The GEA GigaSlicer has an output of up to kg/h. 1 1: depending on product and apllication 39

40 GEA LINE COMPETENCE As a single source supplier, GEA offers complete line solutions for a wide variety of applications to produce attractive, safe and consumer-friendly packs. The line concepts range from low to high output, from easy handling and flexible in operation to ambitious and sophisticated technology with full automation and synchronized components. It goes without saying that the focus for all machine setups lies on efficient production, best possible yield and user-friendly operation always comprising highest hygienic standards. Your performance benefits Single source supplier guarantees performance of complete line concept One speaking partner Global service and spare parts logistics Optional software packages available to increase line efficiency (e. g. GEA LineControl, remote services, condition monitoring)

41 Flexible GEA Line Solutions for every application purpose up to 450 kg output / hour 1... up to kg output / hour 1 up to kg output / hour 1 1: depending on product/application

42 ADDITIONAL EQUIPMENT GEA OptiScan The GEA OptiScan is a pre-scanner system that makes it possible to slice natural products like dry cured ham, bacon and cheese with maximum yield and on-weight portions. The scanner literally looks into the product and determines the density distribution over the length of the product by means of X-ray technology. In this process, the device detects irregular outer contours as well as holes, under slices and irregular distribution of fat and meat. Disruptive factors, such as reflections on the product surface, are not a problem. Based on the density distribution, the intelligent software calculates the ideal slice thickness for each portion prior to slicing. The result is not only exceptionally low give away, but also an extremely high percentage of correct weight portions, thus minimizing the manual work on a slicing line. GEA Check 4000 The GEA Check 4000 is a high precision weighing system, detecting single weights of sliced portions while moving these over the check weigher. The single portion weights are analyzed in the slicer for weight regulation. Thus, the slicer is able to respond to varying product cross sections and optimize the deviation in average weights over a long period of production time. The GEA Check 4000 is available in multiple lane configurations. Weigher programs (recipes) as well as reports are stored in the controls of the slicer and an external USB interfaces makes reading these out easy. All side panels can be removed swiftly without tools for cleaning and maintenance. The weighing system is calibrated for loads between 20 and 5000 g. 42

43 GEA ShingleLoader 600 / 700 When it comes to slicing and packaging at a high output, the GEA ShingleLoader is an efficient system component that feeds the portions fully automatically from the slicer to the thermoformer. The ShingleLoader 600 is economically attractive for automation involving flexible slicing lines in the lower to medium capacity range while the GEA ShingleLoader 700 often makes operation of high performance lines possible in the first place thanks to its uncompromising loading capacity. The reproducible loading precision is a common feature of all members of the GEA ShingleLoader family. This means a wide variety of sliced portions can be fed to the thermoformer via the GEA ShingleLoader. In addition to the loading operation itself, the GEA ShingleLoader ensures continuous production on the part of the packaging machine, in most cases during the entire loading time at the slicer, by means of the integrated buffer conveyors. The consistent hygienic design and simple, quickly detachable belts enable a high degree of product safety through effective and economical wet cleaning. GEA FlexLoader The GEA FlexLoader is a user friendly and space saving loading system, ideal for loading thermoformer or bagging machines. With the GEA FlexLoader, a fully automatic loading of thermoformer machines with sliced portions or pieces is possible. Overlapping or stacking of single products to a complete portion is easily viable. Left-hand and right-hand versions of this machine are available and can be implemented in existing lines or in production rooms with limited space very easily. In the event of changing a format configuration, the operator only needs to select another machine program. The intelligent distance measurement in combination with servo drives guarantees high positioning accuracy. GEA FlexLoader is built in stainless steel for easy wash down cleaning and features pneumatic belt tensioning for fast belt exchange without tools. 43

44 GEA RobotLoader The GEA RobotLoader offers outstanding productivity and almost unlimited options for product positioning. To enable customers to meet these requirements as effectively as possible, GEA has developed a fully integrated delta robot system to handle sliced products as well as single pieces of convenience food. 44

45 ADD-ON OPTIONS GEA slicers can be equipped with a variety of optional add-ons that increase the versatility, flexibility and functionality of the slicers. Many add-ons are also available as field upgrades for existing machines. GEA Interleaver The GEA Interleaver allows interleaving film or paper in-between slices of several applications. Either cheese or expensive products can be interleaved for a nice appearance in the package. The GEA Interleaver is available for GEA MegaSlicer and GEA DualSlicer. Pre-tensioning of paper for long insert of paper or adapted to product contour are optionally available and facilitates a long insert of paper without additional air support. GEA Camera System The GEA Camera System is located in the portioning area of the Slicer. It takes a picture of each slice and calculates the slice thickness based on the surface area of the image in order to get correct weight of the portion. The camera is mainly used for cheese and bacon applications. 45

46 GEA Cross-shingle Conveyor The cross-shingle conveyor is characterized by the movements the portioning part can fulfil. By moving in lateral, forward and backward direction, different contours of portions can be generated. Round circles, overlapped crosswise or meander forms can be easily built with the cross-shingle (also called x-y) conveyor. Folding device (pneumatic) For folding portions, GEA has a pneumaticallydriven folding device which is located in the slicing area. The slice falls onto the device and by use of pneumatic air flow and the speed of the falling slice, it is folded and positioned onto the portioning conveyor. 46

47 LOADING DEVICE As with our slicing portfolio, our loading portfolio can also be extended with various options. Lane diverter The lane diverter is part of the ShingleLoader and diverts portions from left to right or right to left. This is needed if the packaging machine s die set has more rows than the slicer delivers. The lane diverter makes it possible to divert from 1 to 2, 1 to 3, 2 to 4, or 3 to 6 lanes. The Lane diverter can also be used as a spreading conveyor in order to reach the right distance between the portions for automatically loading them into the packaging machine. Formatting Station To overlap 2 to 1 portions with spreading elements. In combination with a lane diverter, it is possible to distribute portions from 2 to 3 lanes. Aligning rake The aligning rake is placed under the aligning conveyor. Pneumatically driven, it is used to align shaved or stacked portions on up to 5 lanes. This shortens portion for increased loading precision. 47

48 Correction Display The Correction Display is a matrix display used to trace missing or supernumerary slices of a portion on the loading area of the packaging machine. It shows which portion needs to be completed manually and with how many slices. UVC Disinfection Ultraviolet disinfection lamps underneath the buffer belts reduce the bacterial counts for higher product safety. Its positioning avoids direct contact with the product for an even more hygienic production procedure. Overlapper A stand-alone overlapping unit positioned before the GEA ShingleLoader provides easy portion overlapping from 4 to 1 or 3 to 1. EasyOverlapper Used in combination with a GEA DualSlicer only. Overlapping portions from 4 to 2 or 2 to 1 with a very small footprint. The Easy Overlapper is controlled by the Slicer. 48

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50 A-TO-Z OF SLICING TERMINOLOGY A - I Blade diameter Diameter of circular blades. Available in 420, 440, 460, 480 mm. Blade radius Radius of the involute blades. Available in 394, 415, 470, 505, 550 mm depending on machine type. Blade surface (coating) Blades can have different surfaces in order to achieve best slicing results. Coating Teflon or hard chromium, depending on application. Down holder A tongue from the top stabilizing the product during slicing (less vibrations). End piece Normally between 18 and 20 mm. The last bit of a product log which is held by the gripper. Ejection necessary after finishing the product log. Folding device A mechanical device pneumatically driven which is mounted in the slicing area to create folded portions. Free angle A specific angle on the backside of the blade. Minimizes the contact between blade and product log during slicing. Give-away The percentage difference between the average weight of all packed portions and the nominal weight. Valuable are all sliced portions minus: - First cut - End pieces - Last incomplete portion (in case of not using portion completion). - Portions with incomplete or destroyed slices due to bad product consistency. Give - away = Average weight accepted *2 - Nominal Weight*portions simultanously measured Nominal Weight* portions simultanously measured 100% Grinding Process to resharpen all different types of blades. Gripper Mechanical part to hold the end of a product log during the slicing process. Idle cut A blade movement without slicing the product. Conventional technology is to stop and retract the product. For high slicing speeds and involute blades, this technology is no longer working without the undesired effect of sliver slices. The patented idle cut rotor moves away the blade from the product, which helps to avoid sliver slices almost completely and to achieve very consistent slice thickness within a portion. Independent drive Together with a multilanes weigher, this option allows different slice thicknesses for the different logs within the same slicing cycle. Infeed belt Belt on which product is placed for automatic feeding of the slicer. Interleaver Add-on device of the slicer which supplies paper or foil in between the single slices of a portion. Possible for portion forms stack and shingle. 50