Meat + Poultry - June 2010 - 52

PROGRESSIVE PROCESSING

materials and run them through a
color sorter and it can remove deleterious materials found in products,"
Zelle says. "We have pasta in many
of our products so we also will be
doing some blanching."
Next, spices, starches, salts and

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spice bags, Zelle adds.
Everything then comes together in
the cook room. "This is where we bring
in the pasta, meat complex, any vegetables, slurry, seasonings and more,"
Zelle says. "They get mixed together

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52 * Meat&Poultry * June 2010 * www.MeatPoultry.com

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and brought up to temperature in thermal blenders. Once we reach the appropriate temperatures, we do qualitycontrol testing to ensure everything is
up to spec. Everything up to this point
has been scanned and tracked with bar
codes so we have accountability as far
as our ingredients go."
Product is then released into a
surge hopper and pumped through
long lines to the fi ll area. The fi ll area
is equipped with three different fillers,
Zelle says. "If we're running a oneshot fi ll, we would go through one
filler. The fillers are [located] over the
line of the Raque tray-line," he adds.

"We have a very
top-end, qualitycontrol staff that
works diligently."
Trays are being denested coming
down the line. The fi llers travel with
the trays and fi ll them. "If it's a twoshot fill, they'll continue on and another filler will fill a particulate, pasta item
or whatever ingredient is required,"
Zelle explains. "Then they transfer
onto the sealing unit of the Racque
line. We take a picture [with a vision
inspection system] to ensure
each seal area
is free of contamination and
we start tracking where that
tray is in that
operation. At
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the end of the
line if there was contamination, [contaminated trays] are automatically
ejected from the line."
Microwaveble trays are fed into the
Racque rollstock film system that's applied and sealed in the Racque sealing unit. "Then we go to the packaging area where a sleeve is applied
on an Aagard packaging system and
that goes into a wrap-around case fed
into the palletizer and onto the pallet
wrapper. Our packaging is modified
atmosphere, not vacuum."

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Meat + Poultry - June 2010

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