IQF Skillet Meals

Problem

Providing a solution that was high-speed, flexible to run multiple different recipes, run production during changeover, and come in under budget. 

“Skillet Meals” come in a very broad variety, and in this case dozens of recipes (and even more ingredients) were required to make this project feasible. High value proteins such as shrimp, toppings such as scallions, sauce pellets or sauce packets were needed in meals anywhere from 4 to 8 ingredients. Automation was required at all levels, and all equipment must be operational in near freezing temperatures.

Solution

A thoroughly designed and engineered line, achieved through collaborating with Ascent and chosen vendors for successful integration.  

A fully integrated line, beginning with totes full of frozen ingredients at floor-level. With a fork truck, totes are elevated 18’ from floor-level to automated tote dumpers/cluster busters above mezzanine levels. The tote dumpers and cluster busters break up large product chunks and feed product into staging hoppers, which hold product until required. Four Yamato O-0324M radial scales split in half and designed for mixing await the ingredients and, utilizing load cells, call for product when the top of the scale is running low. Each Yamato scale will be responsible for two ingredients, and utilizing the split top will produce 2 two-part mixes. 8 vibratory cross-feeders transport product to the top of the Yamato scales, where preset recipes are utilized to weigh the required amount of ingredients. 

Upon successful weighing, the mixed components are discharged from the scale collection buckets (or timing hoppers) into two separate cleated indexing Fraser conveyors below, with each cleat representing an eventual finished bag. In the instance of an 8-part mix, the cleats from both lines will go the length of the 4 Yamatos, communicating and receiving product from all 4 scales to achieve the full required weight of products. From here, the Fraser conveyors transition upward, dumping into two Hayssen VFFS (vertical form fill and seal) baggers, to complete a finished bag.

End of line inspection, both checkweighing for underfilled or overfilled bags, as well as metal detection, are included after both Hayssen VFFS machines, with power rollers included for successful discharge of broken or compromised packages. Viable packages are then transported to the case-packing station, where they are packaged and taken away for storage and eventual shipment.

Sharpe’s client valued speed, precision and versatility for this new line. Having two separate conveying systems, two separate baggers, and split scales allowed for one conveyor (Line A) be stationary while going through a changeover while Line B continues to be operational. All 4 Yamato scales also have the ability to run in a “mono-product” format with a touch of a screen, providing the ability to run recipes with 4,5,6, or 7 ingredients in addition to the 8 part sku’s. Throughput capabilities of having two full lines running simultaneously will more than double capabilities from the client’s existing system on a daily basis.

Results

A fully integrated automated line, set for installation in late 2024 to early 2025.

Sharpe Engineering & Equipment provided our client an automated system, and after several rounds of customer requested iterations and modifications, a full system solution. Sharpe procured portions of the lines for our customer, which will be installed in late 2024 into quarter 1 of 2025.