Think pragmatism

companies

Asahi Sosetsu Co.,Ltd. , JapanMetatek Co.,Ltd. , KoreaAsahi Metatek Food Machinery Co.,Ltd. , ChinaHicook(Thailand) Co.,Ltd. , Thailand

Contact www.hicook.com or www.hicook.co.jp for further details.20

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in yourcutmeat deboning line

From the establishment, the found-ers of our company have aimed at more customer satisfaction by solu-tion-oriented technology and suitable-to-field equipment. This philosophy has backed up all the company man-agement and the entire jobs until now, and of course will continue leading all the company actions.

Early 90’s, the company moved to a strategically significant direction to technically and financially get tied up with a Japanese company Asahi Sosetsu, a top leading manufacturer of industrial class meat processing equipment in Asia. This tie opened a new era for the company in enhanc-ing its business horizon from home to abroad. Lots of projects in overseas countries were successfully carried out and finished with high evaluation and reputation from the users.

Innovative technology is what we seek in our continual research and development, but it is not the end or our final target. Our bottomline always points to whether the offered technol-ogy suits the very user in terms of

its field operation and the marketing requirement. We are not seeking a technology for the technology itself. To do this, we are resolute to choose which is needed and which is not in a manner of pragmatism. Tailor-made system stays a key concept in our business.

On top of these, we have adopted the famous Japanese attitude “putting customer’s value above all” in our 24/7 service system. We are concentrating on Asian markets where we can de-liver timely and fast service in close communication network with our us-ers. Building up the service base has been our prerequisite for our company expansion to any remote territories. Service is not an independent item following the equipment supply. They reach our customer in one package at the same time.

With productivity and maintenance cost in mind, we research and develop, and improve what we have today to of-fer a better solution. In cutmeat debon-ing line, increasing labor intensity and easing labor fatigue could be two con-

tradicting concepts, but because none of these two can be ignored, we are tackling this issue willingly and recon-ciling the two antagonistic concepts. Less fatigue, better yield rate. It is pos-sible as we all put our efforts in scien-tific way of problem-solving.

Hygienic standard is getting more higher and higher in the recent years. Many of our users are in trouble to keep up with such fast elevating stan-dards imposed by governments and authorities concerned. Our cutmeat deboning system clearly fulfills the up-to-date hygienic standard and stays prepared for any later minor adjust-ment and change to a new standard following.

This way we serve our customers and eventually our planet. We will keep going humbly in our path as we have done for the last decades.

Matto factory, Ishikawa, Japan

Nonsan factory, Korea Sales branch, China

Rooted in Asia, focusing on Asian customers

What is going on in Asia is dif-ferent from what in Europe. We deeply understand the situation of the markets here and now. With the typical Japanese cus-

tomer-oriented attitude, has been serving a lot of custom-ers for the last several decades. Everything can be discussed re-ciprocally and progressively. We

and our customers are not in the relationship of sell & buy, rather we both are going up together to a common goal. Your success is our success.

From a unit machine up to a turn-key project, we cover every custom-er’s request. has been the leading equipment & solution sup-plier of cutmeat-deboning line for the last 2 decades. Having adopted

modern scientific benefits into its localized solution, offers well-balanced solutions which best suit each individual customer’s re-quirement and each market’s situa-tion, and its development level, as

each market and each customer deals with its own different reality. Our works include discussion, sug-gestion, solution-offer, equipment setup, after sales service, and mod-ification of the existing facilities.

Updated solutions, yet localized, for cutmeat deboning plants

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Foreword

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It is of our great target to provide our valued customers with “fully func-tional and affordable” hardware and software, as today’s market require-ment change so rapidly and custom-er’s investment would be meaningful only in the case that it is rewarded in a financing manner. What is the use of the “high grade” equipment at the accompanying high costs that can not be sustained? Are they so sure that all the specifications are indis-pensable for the particular customer’s case? Wouldn’t it be more reasonable and logical to offer decently- function-al but low end program in accordance with the customer’s situation and the market requirement? We all should

be smarter, and get focused on the core specification at more affordable prices. For this, every layout is the

outcome of in-depth tailor-made dis-cussion to maximize the efficiency of the investment.

Over the last decades, has built up hundreds of cutmeat deboning plants in many Asian countries. In the year of 1999, it has entered the world largest market constructing the first-ever modernized cut-meat processing plant in the mainland China. Thanks to the successful operation of this first fully computer command line, many following projects in the country were accomplished by our company. We have been the trendsetter of this indus-try here and our specification has soon become the market standard and the referable examples of the copy-cats.

Trendsetting in the cutmeat industry

From a small-scale processing line up to several hundreds pigs/hr or tens of thousands of birds/hr lines, has diagnosed the customer’s status and offered op-timal solutions in accordance with each production scale. Various layouts are often made in the be-forehand mutual technical & com-mercial discussion.

Poultry is another core business sec-tor of cutmeat deboning tech-nology and there are many projects coming up in various countries as in-ternational hygienic standards are get-ting higher. has been strongly linked with many large scale poultry processors in many Asian countries for the last decades, and has installed various kinds of poultry cutmeat debon-ing lines. There is no stereotype layout simply given to a particular customer. Our layouts are the outcome reflecting each particular reality and demand.

Fully functional and affordable Poultry, another rising sector of cutmeat industry

’s primal cutting solution includes three concepts, fully auto-matic, semi-automatic, and manual cutting. There is no given answer on which is the best for you. It should be decided depending on your produc-tion purpose, and its required capac-ity. Even the manual cutting does comply with international hygienic standard such as HACCP and USDA. Cutting knives are specially treated by a professional steel processor so that it assures you of highly reliable durability.For any large scale cutmeat deboning plant, this fully automated primal cutting system is strongly rec-ommended. It brings you the higher productivity and the better yield rate and the entirely-eliminated second

contamination risk. Each carcass is computer-scanned in intercommuni-cation with process-controller in the main computer that would then send back the order for the ideal cutting in the given condition with the car-cass being optimally positioned.In many cases of large production scale plants, however, semi-automation concept should be the best choice. This semi-automation also offers convincible production efficiency and sweet yield rates with less hygienic jeopardy. A laser beam unit indicates the cutting point according to which each carcass should be positioned. Positioning is the only manual job, and the cutting process is performed in the conveyor movement.

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Primal Cutting SuperCutter with Laserbeam

Supercutters perform major cuts over loaded carcass mostly in 3 ma-jor parts, front, middle and rear. Each major part shall be distributed to each work platform by distributing devices. Normally a worker with the Super-Cutter position carcass with the aid of laser beam indicator. The knife of SuperCutter is a precisely processed one that has more than million cuts and also can be used after proper re-sharpening. ’s local tech-nical service team provides this re-sharpening service at a reasonable cost. Equipped with protection cov-ers, the system keeps the worker’s hands away from it.

Carcass loadingCarcass coming out of the slaugh-

tering area are loaded on the con-veyor belt by the loading device. The loading device requires no human la-bor and the speed is adjustable. This is the starting point of carcass on its cutmeat deboning journey.

Primal cutting include SuperCutting and other follow-ing major processes. These jobs influence production efficiency a lot at the following work stations. Tied up with world top supplier of the related tools and devices,

supplies high quality primal cutting accesso-ries.

Pre-work before main trimming jobs

After major cutting process with SuperCutters, products(relatively big cuts) are distributed in pre-de-termined conveyor flows. Distribution can be done by cylindrical movement and/or some guides. Such aspects as the product kind, the number of work-ers at work platform conveyors should cautiously be taken into account for a better layout. A simple miscalculation would lead to great invisible loss in production efficiency at the following process.

All the working platforms and their relevant hardware are well designed for local people’s physical condition

like height and also for less contami-nation risk. Every corner of the hard-ware is elaborately designed and

manufactured in terms of a decent labor intensity so that the manage-ment can make sure of optimal labor productivity. Frames are processed slope-wise(slide treatment), that al-lows no water to remain and no invis-ible and inaccessible place for any kind of bacteria to survive.

◀▲ Standard configuration of 3 layer processing platform conveyor

◀▲ Configuration of packing and weighing conveyor

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Ergonomic working platforms

Ergonomic environment for

deboning and trimming

Each part of the pro-cessing platform con-veyor can be dismantled and washed up individ-ually. The sides and the backside of the belt can also be accessed and visually washed com-pletely. There is no bar-rier blocking worker’s access onto any part of

the platform conveyors. Cleaning covers majority of hygienic control in most food processing factories. Once the systems are designed to get easily cleaned, workers are willing to clean them even without any strict, seemingly-nagging control of management side. First keep the systems clean, that makes any extra hygienic control easier. Wouldn’t it be unwise to put more efforts to clean the systems after you keep them exposed to lots of contamination sources? Once contaminated, it requires much more efforts to get it cleaned. With easy cleaning concept, our system will get less contamination therefore requires less efforts to deal with it.

Less contamination risk

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All the trays are moving around in the line according to computer’s com-mand. All the details such as where they should go and come, how long

they should stay, etc are at on-line networking. Trays are provided addi-tionally first to where they are needed most among all the working lines.

From the packaging line, used trays come to the automatic tray washing system where they will be cleaned with sterilizing agents and hot water, etc, and dried out to get ready for re-turning back to the working lines.

As there are multiple number of working platform lines, trays com-ing out of the tray washer should be distributed into each line. The system has guiding devices that receive the command from the computer. They respond in accordance with the situ-ation of the very right moment. Trays are moving around along the whole lines just like blood travels around throughout human body. Trays trans-port processed and trimmed meat to the sorting and packaging area, and after unloading them, they get back to the tray washer to get cleaned. The tray washer is acting like human lung. This way, the whole system coopera-tively works as a whole continuously. Any unexpected blockage in the tray circulation would be dealt with by vi-sual and audio alarm immediately.

Getting them at the right place and timing

In the tray destination system, the essence of the line is how smoothly trays can be circulated and how pre-cisely they can be delivered to where they are needed at the right timing. The layout design should reflect all the information of the project, not only the information from the processing section, but also from packaging sec-tion and marketing department. We can say meat products move in the cutmeat line, but in other sense we can also say trays are moving there. In the mechanical point of view, the success of cutmeat deboning line highly depends on how well the line can deal with tray movement. The bottomline is secure the right num-ber of trays at the right places and smooth circulation with less contami-nation risk.

Motor protection on demandSuch important parts as motors are protected by a couple of selectable options between see-through plastic cover ,stainless

steel box and combination of these two. Your maintenance jobs can be eased.

Computer-command tray destination

Clean boxFilled boxEmpty box

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Tray washer plays one of the key roles in the tray destination cutmeat deboning line. All the trays, once used, should necessarily return to the tray washer to get cleaned and dried. The trays get upside down before en-tering the tray washer and after pass-ing through it, they will again get up-side down. Tray washing has several sequential sections such as cleaning , rinsing, drying, etc. Some sections could be put additionally on demand.

DIO Tray washers

Packing is the last pro-cess inside the factory per-formance. always first check what would be the best packing solution for each particular customer. All the marketing strategies and tactics are taken into serious account so that the packing line can be designed at a tai-lor-made base. It also include wrapping and shrinking either by machines or manual jobs. There are some experts of this machine kind, and we have been cooperating with them to meet customer’s re-quirement.

For some packing ways of a cer-tain product kind, shrinking becomes a necessary step. ’s shrink-ing machine uses high performance heating blower to ensure speedy film shrinking without getting surplus heat into the meat itself. When it comes to the chilling machine, benefited from the famous PST pasteurizer,

chiller for cutmeat deboning line performs an excellent and stable heat exchange with the shrunken products. Heat applied on the sur-face of the packed products is easily and immediately removed , allowing less possibility for the product to get affected by any unnecessary remain-ing heat.

Packing

Shringking and chilling

Model E2 Box(LxWxH)

Capacity(trays/hr)

A(width) B(length) C(height)A1 A2(water tank+) B1 B2(blower+) B3 C1 C2(motor+)

Dio860+DTR

600x400x200

650(max860)

1,000 1,400

3,910 4,700 5,500

1,600 1,820 Dio1200+DTR 900(max1,200) 5,110 5,900 6,700 Dio1600+DTR 1,200(max1,600) 6,530 7,320 8,120 Dio2200+DTR 1,600(max2,200) 9,200 10,000 10,800

Dimensions (standard type)

UtilitiesModel

Water Steam Electric powerCold

(1~3bar)Hot

(80℃,1~3bar) 3~5bar (3ph,50/60hz)AC380/400

Dio860+DTR

DN25(25A) DN25(25A)

80kg/hr 12.0kwDio1200+DTR 100kg/hr 15.5kwDio1600+DTR 120kg/hr 23.0kwDio2200+DTR 180kg/hr 23.0kw

Dimensions (K type)Model E2 Box

(LxWxH)Capacity(trays/hr)

A(width) B(length) C(height)A1 A2(control box+) B1 B2(blower+) B3 C1 C2(motor+)

Dio-K860+DTR 600x400x80~200 650(max860) 1,000 1,300 3,610 4,400 5,200 1,600 1,820

ModelWater Steam Electric power

Cold(1~3bar)

Hot(80℃,1~3bar) 3~5bar (3ph,50/60hz)

AC380/400Dio-K860+DTR DN25(25A) DN25(25A) 80kg/hr 12.0kw

Utilities

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Where we differ from them

Keeping up with the surging modern hygienic standard is of the essence in today’s food factories. We spare no effort to go with the fast upgrading modern trend and embody it into the hardware of the cutmeat deboning line. Our works involve HACCP, USDA, and other international hygienic standard and the regulations.

Measure twice before you cut

The cutmeat deboning line is not a small scale project. Huge amount of investment usually accompanies the project. In many cases, the project influences greatly and decides the success or failure of the investors’ business. This is not the story about a simple machine that can be taken out easily when any problems are found. The line had better be treated as the factory architecture itself. It consists of hundreds of items and parts, which get together in a good reciprocal combination. A good carpenter mea-sures two times and cut one time. Think twice and ask yourself again what you are really looking for, where you currently stay.

Many Asian customers are apt to look for a solution for their business in other part of the world. In the internet era like this, where all the information are shared by one click in the network, the solution usually stays near you. A good system must be an outcome of great reflection over lots of field experiences. European systems are based on their own field experience, and this doesn’t completely apply to Asian reality. Products, markets, lo-gistics, costs, workers , all these are different. Only the tailor-made solu-tion after comprehending all these aspects as they are, can work for your business.

, rooted in Asia, has been

focusing on Asian customers and will continue doing it. Experience our tailor-made and field-rooted solution here and now.

Board fixer

Slide treatment

Closedvs

Open

Legs vs

No legs

Rival versus

Belts for each use

CIP (Clean in Process)

Belt is cleaned either in pro-cess or cleaning time, while water and/or approved cleaning agent are injected at the end-point.