Mayekawa: Automating the Art of Deboning

Jiro Miguel Kobayashi, International Sales Engineer Specialist, MayekawaJiro Miguel Kobayashi, International Sales Engineer Specialist
The global demand for boneless poultry products continues to surge exponentially. Amidst population growth and rising individual consumption, chicken processing companies need to invest in innovative automation technology to improve performance and efficiency. Consider the manual deboning process of chickens, for instance, which can be a dreadful task for poultry processing industry workers. The repetitive, tedious motion in a harsh environment not only causes serious health issues but doesn’t produce the needed yield for the chicken processing company. On an equal note, the weariness involved in the job makes finding labor tougher than ever before, which is a major challenge for the poultry processing companies.

To address these compelling problems, Mayekawa, a manufacturer and developer of optimal systems and equipment, has come up with a state-of-the-art deboning machine that has completely reimagined chicken deboning in the poultry processing industry through automation.

Built by a team of professionals, TORIDAS, the first-ever automated whole chicken leg deboning machine, has been attracting a number of customers over the years, owing to its unmatched efficacy. This machine stands invincible amidst the swarming players in the market as the only machine with the highest yield ever. Recently in 2019, the company delivered its 2000th TORIDAS to a client, making it one of the most preferred deboning machines in the world.

Founded by the legendary Kisaku Maekawa in 1924 in Japan, Mayekawa, gearing to celebrate its hundred-year anniversary, began its journey as an ice manufacturing and cold storage company. The company offers MYCOM compressors used in industrial refrigeration freezing, heat pump, and gas markets, automated deboning machines under the DAS brand name, and Chorus freezer solutions for a variety of products including seafood, agricultural products, sweets, bread, and prepared food.
“We are able to develop things that most of the companies don’t dare to endeavor because of our company’s structure as a family-owned business, and most of all, our vision for a new world,” says Jiro Miguel Kobayashi, International Sales Engineer Specialist at Mayekawa U.S.A.

Mayekawa has not restricted itself to making just a single type of deboning machine; it has over six different types of deboning machines running across the globe. It includes HAMDAS-RX—the world’s first automated ham deboning machine, turkey deboning machine, TAKIDAS, and chicken front half deboning machine, YIELDAS. Mayekawa has also recently developed a robot loading system, which uses robotic arms to automatically load the to-be-deboned whole chicken legs onto the deboning machine.

Yet another impressive fact about Mayekawa is that it designs and develops most of the technology it uses in building deboning machines, rather than relying on third-party manufacturers. “We make the vision system to detect the ankle position of the whole chicken leg, robot loading system that picks up the legs with robotic arms, and also program these machines ourselves,” explains Jiro.

In one of Mayekawa’s recent installations of TORIDAS for a client in Arkansas, the client was so impressed with TORIDAS’s industry-leading yield percentage that he ended up buying 24 machines in addition to the 12 machines bought previously. With three lines of deboning units, with 12 machines in each line, the client has significantly skyrocketed his ROI.

For the road ahead, Mayekawa plans to introduce other types of deboning machines like turkey deboning machine, chicken front half deboning machine, and pork deboning machine to the US market. With a team of stellar engineers, programmers, and scientists, Mayekawa aspires to revolutionize both the poultry and red meat deboning space with its unparalleled inventions.

Vendor Viewpoints

Why are meat plants investing in automation today?

Jiro Kobayashi, Business Development Advisor, Food Division

Company
Mayekawa

Headquarters
Lebanon, Tennessee

Management
Jiro Miguel Kobayashi, International Sales Engineer Specialist

Description
Mayekawa provides a state-of-the-art deboning machine that completely reimagines chicken deboning in the poultry processing industry through automation. Built by a team of professionals, TORIDAS, the first-ever automated whole chicken leg deboning machine, has been attracting a number of customers over the years, owing to its unmatched efficacy and the highest yield ever. Mayekawa has over six different types of deboning machines running across the globe. It includes HAMDAS-RX—the world’s first automated ham deboning machine, turkey deboning machine, TAKIDAS, and chicken front half deboning machine, YIELDAS. Mayekawa has also recently developed a robot loading system, which uses robotic arms to automatically load the to-be-deboned whole chicken legs onto the deboning machine.

Mayekawa
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