P.PIP.0466 - Lamb DEXA grading with producer feedback, Value Chain integrated system to deliver the JBS "Buy/Make/Sell" Strategy

Summary

JBS Australia developed and integrated a technological transformational whole of supply chain initiative with a commitment to deliver a fully traceable quality product distributing additional benefits to the Australian Red Meat industry and shared across the entire value chain. The planned system will incorporate measuring and processing control systems, utilising Dual Energy x-ray (DEXA) real time sensing as a central conduit of Objective Carcase Measurement (OCM) data for lean Meat yield prediction, product flow automation, complete traceability and cutting specifications. R&D features of the LEAP automation will be incorporated as a platform technology for processing optimisation benefits.

Higher returns and remunerations to customers, processors and producers through JBS’s current and future “Lamb Value Chain Strategy” are projected to flow from plate back to the paddock. JBS will support this initiative through their successful “Farm Assurance Program” where everyone involved, from the 600 individual farming families, the processor and value chain participants are connected to what is being produced, sold and consumed.

Objectives

The objectives of the project were:

1. Designed, developed, installed and commissioned a radio‐frequency identification RFID enabled dual energy x‐ray carcase system (DEXA) that will not only be used to drive the forequarter (bone‐in and bone‐less) processing cell, and ascertain which carcasses should be processed with the new “sticky rib” middle cutting module, but will also provide producer feedback on lean meat yield of their livestock provided by JBS.

2. Re‐designed, developed, installed, and commissioned a bone‐in 10 carcasses per minute square‐cut forequarter processing system.

3. Designed, developed, installed, and commissioned a new “sticky rib” cutting module that will be integrated into the existing middle machine.

4. Completed producer feedback, engagement, and training, to realise a value‐based trading system for lamb.

5. Developed JBS producer network, JBS producer groups, PDS programs connected to the network.

6. Undertaken industry open days, and producer education days.

7. Developed a post installation cost benefit analysis and dissemination video and report.

Key findings

It was found that input carcase quality had a profound effect on the performance of the system (as it also would with manual cutting). Having the DEXA, Primal and Middle system in place has assisted JBS to identify upstream carcase processing issues readily and address them on a timely basis which further adds benefit from the system to JBS business.

The loin deboning process has presented significant challenges to achieve the processor requirements regarding refinement of the removal of product from the skeleton. The viability of the new machine is measured by the yield exceeding current means of boning, such as the BLM machine for eye of loin removal and manual tenderloin removal. These developments are still underway at the time of writing this final report.

Quantitative validation of the yield and uptime has not been possible to date on a processor site or on processor quantities due to COVID travel limitations.

Benefits to industry

The outcome of the project has demonstrated the capability of fully automated and integrated primal cutting, processing of the lamb middles and forequarter processing.

The DEXA data enables the wider project objectives to leverage benefits through the JBS “Buy/Make/Sell” business model. The ability to perform a second cut on larger carcasses and create a short rib product increases the value from the carcase.

The results from the factory testing of the Loin Deboner, after the further development phase, indicate the achievability of a commercial standalone machine that will deliver yield and labour saving. Additionally, once mature, the loin deboning system could be integrated into the SCOTT middle machine.

MLA action

MLA continues to work with AMPC in exploring the application of DEXA and processing efficiencies for the small stock industry.

Future research

It is anticipated that the issues and learnings from this research will further improve future installations by ensuring that correct mitigation can be put in place at the time of installation or during the machine build.

Further research opportunities include:

- Further development of carcass stability and X‐Ray scanning accuracy.
- Application of 3D vision systems for the likes of rib length determination.
- Enhanced accuracy both for X‐Ray analysis and rib length determination.
- Use of DEXA data for value‐add opportunities.