Marel has introduced the RoboOptimizer, a cutting-edge automation tool designed to remove the labour-intensive task of loading portion cutters in poultry processing
This intelligent positioning system works seamlessly with the I-Cut 122 portion cutter, forming a fully automated process from the moment singulated fillets are placed on the belt.
By taking full control of positioning and communication with the portion cutter, RoboOptimizer ensures accuracy and consistency throughout the operation. It doesn’t just handle the cutting—it manages the flow of products downstream as well, making it a comprehensive solution for modern processors.
Traditionally, workers have been responsible for placing chicken fillets on belts, a process that directly impacts the quality of the final product. Inconsistent or incorrect placement would often result in lower yields and poor cuts. RoboOptimizer solves this problem by organising the fillets accurately before they reach the portion cutter. Using a rapid gripper system, it can manage up to 120 fillets per minute across dual belts—an efficiency no human operator can match.
“With RoboOptimizer, we really step away from labour. If the products are singulated, portion cutting can now be done without staff. The system will do the job with much more consistency and accuracy than people could ever do. The operator who loads breast caps into the deboning system could potentially be the last person to touch the meat. RoboOptimizer comes as close to a labour-free solution as possible,” says Morten Dalqvist, Marel Product Specialist.
The system features a laser vision scanner that covers an 800 mm-wide conveyor. It measures each fillet’s size and orientation, even distinguishing between left and right fillets—a Marel-patented feature. This distinction is vital to preserve meat fibres and avoid damage during the cutting and tumbling stages.
“Optimising the angle of each individual fillet can give a significantly better yield for strips,” adds Dalqvist. “There are fewer off-cuts because we can optimise the right strip length all the time. Before, we used to cut a fixed trim of a certain size to ensure that the first strip met the requirements. By using the RoboOptimizer, we can reduce this trim to a minimum and still ensure the correct strip length. This eventually increases the overall yield.”
Faulty or misaligned fillets are also filtered out before reaching the cutter, preventing downstream issues. The system then uses strip-optimising software to determine how each fillet should be used—whether for cubes, burgers, or precise strips—maximising both yield and product quality.
Factories relying on manual loading for portion cutting, especially in QSR, food service, or retail production, stand to gain significantly from adopting RoboOptimizer. With full integration for sorting, trimming, and routing, and virtually no labour required, it redefines automation in poultry processing.