Auto Carcass Chillers

Mechanised chilling allows the automated transportation of carcases through the chilling room on a batch, semi-batch, or continuous processing regime. Mechanisation is readily justified for new chiller installations, and in some circumstances can be retrofitted to existing manual rail systems.

Each system is designed to suit each Plant’s intended tenderness requirements, processing rates and operating and grading regimes.

The auto carcass chiller conveyor system can be used for a variety of applications including:

Our prime motivation for the original and continuing development of this automatic carcass handling system has been to reduce ongoing labour and operating costs by improving efficiency while maintaining product quality.

The Realcold system is designed around production requirements that set the number of chillers, their size and the marshalling floor size.  Carcases are transported to each room, and from the header conveyor transferred to a parallel series of Walking Beam rails.  These index carcases forward as required.

The rooms can be zoned so that the chilling cycle starts from when carcases enter the room and the cycle is progressive as carcases fill the room.

On completion of loading, the cycle simply continues, as it does during unloading so all carcases are uniformly chilled and aged.
For unloading, the Walking Beam system transfers carcases to a header rail progressively, and they are conveyed to the marshalling and cutting areas.

This system is fully automated (mechanised), provides for minimum staff numbers, minimum human carcase contact and near uniform cooling and ageing regimes.

Advantages:

Some of the advantages of installing a Realcold system are:

• Automated carcass handling.
• No manual handling of carcasses, hence reducing bacterial contamination and therefore extending shelf life.
• Installed new or can be retro fitted to existing manual rails.
• Up to 7000 carcasses in one room.
• Totally "in line" system. Operates on the "first in", "first out" principle, meaning all carcases receive exactly the same time/temperature treatment.
• Refrigeration is operating during loading and therefore there is minimal risk of condensation, particularly if the room is "zoned" along its length to provide the exact cycle requirements.
• The mechanised chiller has 100% utilisation, with no loss for sorting or loading/unloading requirements.
• System is simple to automatically sort at relatively low cost.
• Rooms do not need reheating between batches of carcases.
• This is a lower cost solution.
• There are considerable building cost savings associated with a well designed auto chilling system with 25-50% reduction in building size and cost. This usually "pays" for the mechanisation.
• All carcases are aged for approximately the same time, and therefore will have similar tenderness scales.

Click here for our Auto Carcass Chillers Brochure