Case Studies
Chill factor
The latest chapter in a 15-year partnership between the two companies, a new Marel system and SuperChiller have revolutionised processing at Norway Seafood’s Stamsund plant
When Norway Seafoods decided to embark on a redesign of its Stamsund processing plant early in 2010, the company turned to long-time technology Marel partner to spearhead what was effectively a revolution in the facility’s operations.
A wholly owned subsidiary of Aker Seafoods, Europe’s largest whitefish harvesting group, Norway Seafoods operates five whitefish and two saltfish processing plants in Norway, two processing plants and a fish reception facility in Denmark, and two processing plants in France.
Set amid the starkly beautiful surroundings of Arctic Norway’s Lofoten region, the company’s Stamsund facility consumes some 9,000 tonnes of cod, haddock and saithe annually, offloaded straight from trawlers at a quayside only a few metres from the plant’s entrance.
This raw material is processed into fresh and frozen fillets, loins, portions and tail pieces, all destined for markets in Scandinavia, France, the UK and rest of Europe, where the company’s customers include some of the continent’s largest and best-known food retailers.
Founded in 1864, the factory has seen many changes during its 146 years in operation, none more so than in recent times.
“When I started working here in 1992, we produced only wet salted fish and fillets,” says Claus Schive, the plant‘s managing director.
“In 1996, we installed a new Marel processing system which created the opportunity to process fresh and frozen portions, and we began doing so in 1998. Recent years have seen a marked increase in market demand for fresh product, and the installation of our latest Marel production system with the SuperChiller comes as a direct response to this trend,” he adds.
Claus Shive, managing director, Norway Seafoods Stamsund.Rapid installation
“Planning on this latest upgrade of Stamsund plant began in conjunction with Marel in early 2010, and installation began in the autumn,” says Aker Seafoods executive vice-president, production, Johannes Palsson.
“Looking back, it was a massive undertaking involving a complete physical and logistical renovation of the plant, as well as the installation of a new production system,” he continues.
“Effectively, what we did was build a new factory in only six weeks,” agrees production and quality manager Paul Hauan. “Before embarking on the project, we’d looked at the newest technology and were convinced of the potential benefits for ourselves.
“Among other things, the project involved the replacement of our existing equipment with a state-of-the-art integrated processing system, which includes a SuperChiller, a new type of skinning machines, new pre- and post-portioning machines, and a new trimming flowline.
“To maximise our investment, we initiated an extensive programme of staff training on subjects ranging from microbiology to the practical aspects of processing, in an effort to prepare our workers for what was effectively a completely new way of working.
“At the same time, we also introduced new staff rotas and working practices, meaning that production now continues uninterrupted throughout the working day,” he says.
Optimised product mix
Before entering the filleting line, fillets pass through the Marel SuperChiller for 8-10 minutes, where they are cooled to a constant temperature of between -1°C and -1.5°C through skin-side contact with the Teflon belt and the cooling airflow. When they emerge, they are firm, elastic, robust and ready to proceed through the rest of the process without losing their natural juices.
Specially made for superchilling, the new Marel skinning machines are also designed to gently handle several different species of fish.
However, the SuperChiller is about much more than producing a more aesthetically pleasing product. After separation from the fillets by a pre-cutter, the valuable tail pieces move on to an inspection line before being graded and packed.
“The pre-cut has helped us very much both in terms of being able to create new products,” explains Paul Hauan.
“Under the previous system, the whole fillet, tail included, went straight to the trimmers. When you consider that the tail accounts for about 30% of the total weight of each fillet, you see how valuable it can be.
“Using the old equipment, it was almost impossible to process tails as we do today. Our older skinning machines almost destroyed the tails, and we had to perform the tail cut manually. We also missed the target weight, because we didn‘t have the necessary equipment to measure it. Controlled by Innova software, the new Marel I-Cut portioning machines have taken care of this, and the results, particularly with regard to haddock, have been nothing short of amazing
“At the same time, we’ve increased the volumes of the trimming lines by 18-20% through an optimised product mix and greater product quality. The system is also highly flexible, allowing us to change and run several products at the same time.
“In fact, I would describe this new technology and the equipment delivered by Marel as more or less a revolution,” he adds.
Temperature control
Hauan is equally enthusiastic when discussing the effects of the Marel SuperChiller.
“I would also call it a revolution,” he says. “It keeps the fillets, especially the loins, together in a much better way than before, while product shelf life is increased by 1-2 days, a huge consideration given that all our products are transported entirely by road.”
“Under the previous system, fish sometimes sat on the trimming line when workers went on a break, meaning that the temperature of the fillets could rise, especially in the summer months. Now we‘re achieving a constant temperature of around zero and below. In fact, tests we ran recently showed fillet temperature levels to be consistently between -0.7 and -1.0° C.”
As the man responsible for the daily operations of the plant, Hauan is equally enthusiastic about the Innova production software which forms the brains behind the Marel system.
“I use Innova every day, and we’re now about to add another module to include stock control in our warehouse. It allows me to sit in the office and monitor the operations of the entire plant, and also send messages to individual trimmers if their performance isn‘t up to scratch. Thankfully, the communication is only one way,” he laughs.
“The amount of information generated by Innova is massive, and one of the biggest challenges is actually learning how to use it to maximum effect,” he adds.
Hands-on support
One thing on which all three men agree is that implementing so many changes at the same time was a process that brought with it its fair share of challenges.
“As you’d expect on a project of this scale, there have been a number of teething problems,” says Johannes Palsson. “The last few months have definitely provided a stern test of cooperation between Norway Seafoods and Marel, a test I believe that we’ve both passed with great success. A Marel specialist has been on hand to support us throughout every stage of the planning and installation process, and continues to provide us with hands-on support today.
“In essence, the system has exceeded our expectations. We purchase around one-third of our fish from Aker Seafoods, and the integrated Marel system is now playing a key role in making Stamsund an active link in the company’s value chain of harvesting, processing, sales and distribution. As a result, we’re entering 2011 with a strong sense of optimism and anticipation,” concludes Aker Seafoods executive vice-president production, Johannes Palsson.
For more information about Norway Seafoods please see www.akerseafoods.com
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