Report Detail Page

SmartShape shaping of both cold and hot boned primals so as to create innovative red meat products

Background

As part of the MLA/MWNZ joint eating quality program, several R&D prototypes were trialled so as to stretch primals in order to improve eating quality (see the SmartStretch R&D reporting).

Despite extensive testing in numerous production environments, MLA was unable to consistently improve eating quality in all cases, with eating quality improvements restricted to only some primal types.

During production trials of the SmartStretch machine a commercial opportunity was identified in the shaping of primals, regardless of any improvement in eating quality. This ocurred because stretched meat held tightly for more than 12 hours in a package will retain its share even when removed  from a bag.

This has the following advantages:

  • Portion control
  • More attractive plate presentation
  • Ability to provide standarised sizes for the food service industry

Adoption

Extensive industry consultation and product trials were funded, as well as a comprehensive cost/benefit analysis process. The technology is branded as SmartShape, and the current shaping machine is licensed to a manufacturer in New Zealand.

Several units have been sold to processors in Australia and overseas.

However, it is unlikely that there will be much further commercial adoption of this technology until the following is addressed:

  • Machine throughput is increased to 4-6 primals per minute.
  • Labour requirements are reduced via further automation such as automated feed in and feed out and auto bagging (currently being trialled via a prototype).
  • Lower machine cost via a revised machine design and some value engineering.

Further development of the technology

Current machine throughput is around 2-3 primals per minute, and various projects have explored increasing this speed via either add-ons (such as automated bag feeders) or an improved machine design. Under project P.PSH.0602, a horizontal design was put forward utilizing the flow through principal to speed up production rates and two methods of feeding this horizontal version were developed. One feed system used a "spoon" type feeder to place the meat portions into the compression rubber, the other used a continuous belt feeder to transport the portions into the compression rubber. A horizontal system was built and fitted with each of the above feed systems, but provided limited throughput and packaging benefits.  No further work was carried out on this design.

Several other shaping machine designs have been considered, but none of these have progressed to a prototype stage.

Downloads

Title Size Date published
1.3MB 01/06/2011
1.5MB 01/08/2012
292.4KB 01/05/2013
170.2KB 01/06/2010
440.1KB 01/05/2012
2.0MB 01/10/2008
415.9KB 24/08/2016
1.2MB 01/01/2010
2.7MB 01/08/2012
223.1KB 01/01/2006
1.0MB 03/11/2016
5.0MB 01/10/2008
163.0KB 01/07/2010
586.8KB 01/06/2012
189.1KB 01/06/2011

Contracts

Contract No. Title Start date End date Funding type
A.MPT.0055
SmartShape auto bagging system (stage 2)
01/08/2012 09/09/2013
Industry
A.MPT.0057
CMA: SmartShape demonstration program
30/11/2012 30/06/2014
Industry CMA
A.MPT.0046
Alternative Meat Shaping Technology Design
23/01/2012 15/02/2014
Industry
P.COM.0132
SmartShape (previously MWST)
03/07/2006 01/11/2026
MDC PSH
P.PSH.0602
SmartShape Commercialisation - Stage 1
07/02/2011 16/12/2011
MDC PSH
P.PIP.0399
Smartshape auto bagger – Teys Australia Beenleigh (New vs Old Smartshape design)
03/03/2014 26/02/2015
MDC PIP
P.PSH.0691
Top Cut - Smartshaped Beef proof of concept evaluations
27/10/2014 16/10/2015
MDC PSH
A.MPT.0043
CMA - DII Smartshape demonstration workshop
23/03/2011 12/03/2013
Industry CMA
A.MQT.0061
SmartShape R&D/demonstration machine
03/11/2011 20/09/2012
Industry
P.PIP.0284
CAR8 - Cargill SmartShape Stage 2 – Production Prototype
10/04/2011 06/03/2013
MDC PIP
A.MQT.0047
Technical support for scheduled SmartShape & SmartStretch technology demonstrations to targeted early adopter processors
01/10/2009 30/06/2010
Industry
A.MQT.0059
CMA: MQST Innovation transfer
01/07/2011 21/06/2012
Industry CMA
A.MPT.0005
CMA SmartShape WA demonstration
01/08/2010 30/06/2011
Industry CMA
A.MPT.0037
CMA - SmartShape workshop
15/10/2001 30/11/2010
Industry CMA
A.MPT.0042
Determine Feasibility and Develop Process Protocol for Cold Set Binding Using Smart Shape Technology
15/04/2011 24/06/2011
Industry
A.MPT.0053
SmartShape CBA model enhancement
01/01/2012 31/01/2012
Industry
P.PIP.0253
CAR7 - SmartShape Raw and Injected Beef Product
19/04/2010 30/06/2011
MDC PIP
P.PIP.0263
HW Greenham SmartStretch and SmartShape meat product development for Australian and export markets
01/02/2010 30/06/2012
MDC PIP
P.PSH.0533
SmartShape raw roast beef product development
20/01/2010 30/06/2011
MDC PSH
P.PSH.0534
SmartShape cooked meat product development
01/11/2009 30/06/2011
MDC PSH
A.MPT.0044
CMA: SmarShape Interactive Presentation
21/04/2011 30/06/2011
Industry CMA
A.MPT.0045
CMA: SmartShape Interactive Presentation
01/07/2011 11/05/2012
Industry CMA
A.MPT.0054
SmartShape auto bagging system
01/01/2012 21/06/2012
Industry
P.MDC.0002
Assessing the potential value of Boa Technology to Australian Red Meat Industry
25/09/2008 21/11/2008
MDC PSH
A.PNT.0101
Restructured Meat Product and Process
12/02/2004 04/09/2006
Commercial
A.PNT.0054
DNU - Meat Stretching Device
24/07/2006 04/09/2006
Commercial

This page was last updated on 19/09/2018

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