Meat2.0 New Concept: Meat Factory Cell

The concept is completed and has been presented (www.animalia.no). Norsus (fka Østfold Research) conducted a Life Cycle Sustainability Assessment (LCSA). Data related to energy use, HSE and economy was collected from Nortura Tønsberg, the databases Ecoinvent, Agri-footprint, Agribalyse, the Product Social Impact Life Cycle Assessment (PSILCA) database, and other relevant literature. A scientific article comparing the Meat Factory Cell concept (MFC) with conventional slaughter and butchering was published by Journal of Cleaner Production. The LCSA analysis showed that the difference in environmental impact was insignificant, and that the MFC is predicted to be more cost effective for small and medium slaughterhouses, improve the HSE and require new competence. Møreforsking analyzed the internal logistics for MFC and focused on how various tasks within the cell may be organized and optimized between the operator and robot. This involves the optimization of the sequence of the various operations, the number operative cells and when the operator should move between the cells to work in another cell, or wait in the cell to let the robot carry out its operation. Møreforsking developed a description and method which calculates optimized or close to optimized solutions. Studies show that the MFC concept has an impact on the slaughter and cutting process. In 2019 there were six main trials at Nortura Tønsberg conveyed to evaluate and document the consequences MFC slaughter has on meat quality. The products in focus were tenderloin, pork belly and ham as a selected processed product, as well as cutting in general. Pork belly was a challenge when it came to cutting the skin into a cubed pattern. During the main trials there was also an issue with poor bleeding out after slaughter (not related to MFC). Residual blood resulted in a visually bloody product when the pork belly was vacuum packed warm. The pork belly also had a metallic off taste when analyzed by a sensory panel. Better bleeding out, a controlled cooling regime, trimming and cutting the skin later, will probably alleviate these issues. Deboning the limbs was effortless and gave a higher yield compared to cold cutting, and if used directly into further processing it will reduce costs related to cooling of products. Sensory analysis of ham did not differ from control. The tenderloins were vacuum packed warm and cooled with the conditions that were available to us for these industry trials. The products were cold-shortened and less tender. Optimizing cooling of the various products from MFC may resolve this issue, and energy usage and cooling capacity is expected to be halved. Hygiene was analyzed by comparing 29 MFC slaughtered pigs to 29 randomly selected pigs slaughtered conventionally. The trial pigs were swabbed immediately after being cut and placed on the rack, whereas the control pigs were swabbed immediately after weighing and classification. Both slaughter methods resulted in very low microbial values, and the MFC samples were numerical lower, however not significant. A scientific manuscript with the results from the cutting trials in Tønsberg is currently underway. The local Food Authority participated in trials and shared their thoughts and ideas on how the slaughter may be presented in the best possible way for inspection. A simulation model for both conventional slaughter and cell concept regarding time use, need of operator, etc. was developed. The model will be a valuable optimizer for conventional slaughterhouses and cutting businesses. A digital final seminar for all project participants, where results from all work packages were presented, was completed in June 2020.

MFC-konseptet er blitt plattformen for KPN-prosjektet MeaTable ledet av NMBU og oppretting av en Automatiseringslab på Realtek-fakultetet. Videre har partnerne, som følge av Meat 2.0, fått et betydelig EU-prosjekt (RIA) kalt RoBUTCHER hvor målet er en fleksibel, robust, skalerbar og kognitiv fullautomatisert MFC-prosess. Interessen fra Kjøttbransjen og leverandørindustrien er god, og det disruptive konseptet møtes med interesse og nysgjerrighet fra både norske og utenlandske aktører.

Meat 2.0 will develop a game-changing production and processing method that addresses the current needs and future trends of the Norwegain meat industry. The Norwegian industry is required to constantly improve productivity. Traditional solutions are not sustainable in a longer perspective, and Norwegian industry has to explore new holistic concepts relevant to the prevalent Norwegian conditions. In a global perspective it is also a question of food security. We need to develop efficient technology to utilize important resources in smaller as well as larger regions for sustainable food production. The project will investigate reorgansising from production lines to workstations - the concept of the Meat Factory Cell (MFC). MFC will apply three principal changes to meat production and processing: 1. Work will be mainly organized in cell stations. Today work is mainly line organised along conveyors. 2. Combine and merge elements of the today's separate processes and disciplines "slaughter", "meat cutting" and "deboning". 3. "Disassemble" the carcass from outside-in. Today, the focus is to firstly remove internal organs before presenting "an intact carcass for control". The concept shall be more profitable, efficient, environmentally and socially sustainable, flexible handling even different species in one set-up, beneficial for operators' health, environment and safety (HES), improve hygiene and provide meat quality from tailored processes for each cutting part. Relatively high wages also calls for automation solutions with lower investment barriers for small-scale Norwegian factories. MFC will also be a solid and dynamic foundation on which to build improved production and automation.