A contemporary and safe production environment requires a quality tipping skip that meets all applicable safety, CE and food safety standards. Its operation is in need of improvement, as well, by avoiding the rind falling apart next to the shredder, working more ergonomically and having the tipping skip’s loading platform at floor level. The existing, 20-year-old tipping skip no longer meets these requirements and consequently needs replacing.
Currently, to tip the frozen rind into the shredder, the plastic foil is removed from the pallet right before it is forklifted into a half-open skip / chair. Grippers clamp the pallet as the tipping skip is lifted and then tipped into the shredder. Using this method sometimes causes the stack of rind to come apart when the foil is removed or the stack is lifted into the skip, which has a platform height of ca. 50 cm.
The existing tipping skip is made of steel with a stainless steel coating where the rind comes into contact with the metal. The structure is badly affected by its corrosive environment, with various parts proving difficult to clean.
For the production of gelatine and collagen, pork rind is imported from various locations in Europe. While fresh rind can be used directly in production, frozen rind has to be put through a shredder which grinds the large block (>1m³) down into smaller pieces.
The supply, storage, workflow, disposal of cardboard / plastic / palettes / bins, ergonomics and safety are all important factors of the project, and instrumental in determining the specifications for the new tipping skip. The entire production hall and its machinery were 3D scanned in great detail to ensure that the complete design fits perfectly.
The new version of the old tipping skip was designed in full accordance with the latest safety requirements and regulations for machines in the food processing industry. The new tipping skip, which is now entirely made of stainless steel, employs new techniques to simplify its use. Pallets with rind are loaded onto the platform - which is now at floor level - in their entirety and fully packaged. This allows for the use of a simple transpallet instead of a forklift. The entire tipping skip tilts backwards. When the shrink wrap is cut, and the stack comes apart, the rind now falls into the tipping skip. A water jet only slices the back of the shrink wrap at the exact moment the skip is lifted.
Further enhancements include better cleanability, an improved user interface, increased safety, the ability to dump in fresh rind…
The installation of the tipping skip should be done with extreme precision. There is only a window of a few days during which everything has to be installed and connected. In the run-up to that moment, several short stoppages are possible, but the majority of preparations have to be carried out during the processing of fresh rind.
Once the old tipping skip has been removed, only fresh rind can be processed, which requires a tremendous amount of preparation and planning on the part of Rousselot. From that moment on, any work should be carried out in a manner that is 100% hygienic and shielded from the rest: concrete works, preparation of electricity and hydraulics, ceiling adjustment … with the acceptable margin of error set to virtually zero.
As for the tipping skip itself, it is deployed and fully tested on the supplier’s site, to ensure a plug & play installation during final deployment.