Tag Archives: carcases

New venison plant for Alliance Smithfield

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Alliance Group’s $8.6 million new venison plant at its Smithfield site, near Timaru, is now operating at full capacity.

New Zealand’s leading meat processor and exporter is processing up to 420 carcases a day at the plant, which serves the company’s upper South Island suppliers.

Until now, Smithfield has only processed sheep and lamb, so the venison plant marks a major milestone for Alliance. More than 50 workers are based at the venison plant, which operates most of the year.

Murray Behrent, general manager of livestock says: “Alliance Group has invested in Smithfield as part of its dedication to delivering exceptional product quality and food safety standards. It is also a reflection of our confidence in the region and we have received great support from our suppliers, who are producing the quality livestock that we require.”

“Smithfield is yet another example of Alliance Group’s ongoing investment to ensure we meet the needs of our suppliers,” he adds.

The outlook for venison remains positive and the investment at Smithfield showed the company was focusing on processing a variety of products for global markets, says Behrent.

ViaScan to be installed at Smithfield in the next year

The new venison plant was built to accommodate Alliance’s innovative ViaScan meat scanning technology, which will be installed within the next 12 months at Smithfield, the company says.

ViaScan visually analyses carcases measuring the lean meat, fat and bone, to capture yield performance levels. It has been available since 2003 for analysing sheepmeat, and is already in use at eight Alliance Group plants. The company announced it was first to be extended to its venison suppliers at the Alliance Makarewa in Southland in July this year.

Along with providing suppliers with the opportunity of improving returns, ViaScan also aligns farmers with current market information and helps them with decision-making and the selection of good genetics.

“Exceptional product quality and food safety standards are vital for Alliance Group’s export market,” said Behrent when announcing the move. “We’re targeting high-end consumers with discerning palates who rate meat quality highly when making purchasing decisions and ViaScan helps our suppliers produce the quality livestock that is required.”

ViaScan will also mean suppliers can measure the performance of each individual carcase, particularly when the National Identification and Tracing Scheme (NAIT) is introduced in February 2013 for deer, says Behrent.

Smithfield is one of the three Alliance premises selected by Marks & Spencer to provide chilled New Zealand lamb for its UK retail stores. It is also one of the five first plants to introduce the new Ovine Post-Mortem Inspection system of sheepmeat carcase checks this year.

In 2011, Alliance Group completed a $15 million project to upgrade its Mataura beef plant in Southland.

‘Meating’ the plastic challenge

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A series of challenges has been thrown out to the plastics industry to develop packaging that will help the meat industry maintain high food safety standards, increase shelf-life and develop new products.

The meat industry is one of this country’s biggest users of plastic, particularly in the form of packaging that keeps products safe, fresh and looking great right to through to the customer.

Speaking to the Plastics New Zealand conference in Queenstown in May, Meat Industry Association chief executive Tim Ritchie outlined where he thought future opportunities lay for the material.

He told delegates that the meat industry has been very responsive to market demands and there has been a very significant change in the business model over the last 25 to 30 years. Trade has moved from sending frozen carcases – which, early on, were simply stockingetted and later shrink-wrapped for shipping – to the UK, to now sending chilled and frozen cuts and ready-prepared products to more than 115 markets around the world, with a growing focus on the Asian region, he explained.

“Now, we are in the business of directly servicing supermarkets with quality, consumer-ready cuts of meat, produced and packaged at source in New Zealand.

The industry is now in the ‘disassembly’ process, exporting and marketing the ‘bits’ around the world so as to maximise value, he said, adding that “a steadily increasing proportion of trade is high value chilled product.”

Ritchie said that plastics are widely used in the production process, covering products such as clips, liners, covers, containers, crates and pallets, “ensuring that processes are as clean as possible while meeting the needs of industrial production for items that are lightweight and resilient.”

There is a need to ensure their biodegradability and detectability. “But the greatest opportunities for the future of plastics in the meat industry are probably in packaging,” he said.

Areas of opportunity lie in safety, shelf-life, environmental sustainability and, finally, product quality and presentation. Reducing costs and lifting efficiencies are also part of the equation.

A growing volume of New Zealand meat is chilled and it is vacuum-packaged and sometimes CO2-gas flushed.  “The use of barrier bags and gas flushing were important steps in the evolution of our business.”

New packaging that contains anti-bacterial agents, such as ‘biophages’, and ‘smart packaging’ which can identify changes in the product and alert consumers if there is a problem, are two new areas where manufacturers can assist the meat industry to maintain high food safety standards, according to Ritchie.

Shelf-life is another area which has become even more important especially for the perishable chilled meat trade, as the global shipping industry moves towards greater use of ‘slow-steaming’, which increases transit times and reduces the remaining shelf life of products once they get to market. He noted that packaging companies already working on solutions with shelf-life enhancing properties.

In addition, consumers are increasingly demanding environmental sustainability, which means reduced and/or recyclable packaging. Food waste, identified as a major problem especially by the European Union, is also an issue.

“But a significant amount also occurs after purchase and here packaging can be part of the problem,” Ritchie says. Packaging sizes for single or fewer portions, for example, or re-sealable and compartmentalised packages can help limit unnecessary waste.

“And then there are bio-plastics, such as those being made from meat by-products.”

It is not just being satisfied ourselves that all is sustainable and safe, said Ritchie. “We need to be able to demonstrate it to the consumer and retailer, who is often proxy for the consumer in this business.

“Plastics can play an increasing role in helping with food safety, extending product shelf-life, improving attractiveness and ease-of-use by consumers. At the same time, our industry increasingly needs products that are environmentally sustainable, with recyclable or biodegradable attributes,” he concluded.

“And of course, anything your industry can do to help us take cost out of the system and improve operational efficiency will be welcomed.”

This article has appeared in Food New Zealand magazine (October/November 2012).

Doing whatever it takes

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Adept beef clipOver 400 visits to meat plants here in New Zealand and around the world, up to his elbows and covered in blood and guts, have paid off for Adept clip inventor and managing director Murray Fenton.

Now used widely in meat plants throughout the world, the device reduces or eliminates contamination from gut contents during processing. The clips were first made in the 1970s after a call from a slaughter board supervisor at a local lamb processing plant. In 2009, the company announced that the billionth clip had just rolled off the production line (see Food NZ magazine, June 2009).

Appearing in a video interview alongside three other plastics industry leaders in the latest offering from Leaders Review, Murray says the first plant managers initially didn’t even bother dragging themselves out to see what he was doing. So it was a matter of standing there by himself, getting covered in the worst substances imaginable, stoically applying his new design to the carcases. That was until the the result and the effect on the production process became obvious. “Gustsy! Literally,” says Leaders Review‘s Peter Anich.

“Three out of the four plastics leaders made a point of not calling themselves ‘sales’ folk of any shape when when they started out. In fact, they described how downright awkward about this crucial process they had been. Innovation and product conviction pushed them forward anyway.”

Adept’s website states that of its meat industry products, meet EU and FDA Food-Contact requirements and are compatible with all rendering systems.

View the interviews at Leaders Review – Plastics Industry.