Production capacity of final products
- pieces of prosciutto
- of cured salamis
- of other cured meat
Prosciutto production plant
Long-time preparations and developments resulted in one of Europe’s most cutting-edge prosciutto production plants.
The plant itself is automated, equipped with an automatic line for the production of prosciutto, upon which only previously selected raw material of strictly determined weight can be uploaded. The weight of raw material is important for the regulation of the salt level in the prosciutto. Our goal is to create a high-quality product, which is appropriate and safe in terms of health, and which contains only meat from the hind leg of a pig and salt from the Adriatic Sea. The meat is previously massaged, which softens the tissue and enables uniform salt absorption. No chemicals, preservatives or any other additives are used in the production of prosciutto. Meat does not undergo smoking process.
Inside the plant, there are four robots designed for the placing of pig legs on the racks and two additional, automatically controlled robots, which categorize the legs according to the specific stage of the production process. Another role of this system is to weigh the racks with legs, which enables monitoring of the product weight loss. The ripening process takes place in seven different rooms and it goes through seven different stages under completely controlled conditions. High level of hygiene is guaranteed thanks to the automatic rack washer, while the product itself goes through an automatic washing stage. Before product shipment, the procedures of quality control and automatic palletising are conducted.
Plant for production of cured salamis
Plant for production of cured salamis, with or without mould, has been designed and constructed in line with the world’s highest standards. At the entrance to the plant, a detailed quality control of raw material is performed, after which the latter is placed in tempering rooms, in order to make sure that the production process itself is resumed in optimal conditions. The processing line is equipped with scales, which ensures high degree of precision, uniform distribution of spices throughout the batch and homogeneity of mixtures by mixing under vacuum – all this with a minimum increase in the temperature of raw material. On the automatic line, products are stuffed into casings and are then moved into a drying room. Weight loss of the product is carefully monitored by regularly weighing of racks with salamis. At the end of the process, the whole rack is cleaned and the products go through the final control phase.
Plant for production of cured meats
Plant for production of cured meats, with or without mould, has also been designed and constructed in line with the world’s highest standards.
The receipt of raw material is characterized by a detailed control of every piece of meat, after which the meat is moved into tempering rooms, so that the optimal conditions for the resumption of production might be reached. Tempered raw material with spices is mixed and massaged by the pulsating vacuum system, in tumblers, which results in pieces of softened meat ready to be stuffed into casings and nets. By means of two automatic lines for stuffing, compact products of a uniform cross-section are obtained, which are then moved into previously prepared drying rooms by means of an automatic movement system. The next stage of the process is closely monitored and the control of different parameters is performed at every moment of drying and ripening. Upon completion of the ripening process, racks with products are washed in a washing device, and the products go through the final control phase before being placed on the market.
Plant for cutting and packing of cured meats
Plant for cutting and packing of dry-cured meats consists of several interconnected units, which ensure their health safety and permit full monitoring of traceability within the production process. The deboning section represents a separate unit in the plant, where, along with the automatic line for the washing of prosciutto and a series of devices that facilitate the process itself, skilled hands of butchers are indispensable, shaping the prosciutto each time into one of the three final forms that are available to the customer.
Apart from preparation rooms, where a strong emphasis is put on the proper tempering of products, with the goal to achieve large production capacities, as well as quality appearance of the product, the equipment in pristine clean rooms represents the heart of the plant, since it ensures microbial stability of the packed product, accompanied with a high level of automation of the cutting machine, as a result of which the human contact with the finished product is reduced to a minimum or completely avoided.
The plant includes six packing lines, in order for us to be able to offer our customers vacuum packaging, modified atmosphere packaging or flow pack wrappers.
Storage of finished products and their shipment are performed with the help of highly-automated racking systems that enable quick, efficient and stable flow of packed goods from the plant.