Boosting Efficiency in Poultry Processing: SameGram's Weight Sorter Success in Turkey

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Issue Time: 2025/9/18 14:39:51

Summary

This case study highlights how SameGram's explosion-proof 6-lane checkweigher enabled a leading Turkish poultry processor to achieve precise product sorting, improve efficiency, and ensure compliance with strict safety standards. By integrating flexible and accurate weighing technology, the factory reduced giveaway by 12% and increased throughput by 18%, while maintaining consistent product quality.

Boosting Efficiency in Poultry Processing: SameGram's Weight Sorter Success in Turkey

During the transfer test, workers put the turkeys on the Samegram weight sorting scale for testing.

Background

A major poultry processor faced increasing demand for turkey products and was under pressure to expand its production capacity while maintaining strict standards of accuracy and compliance. Relying on manual sorting was no longer feasible. The process was slow, inconsistent, and costly, making it difficult to scale operations and ensure product quality.

Flexible

Six-level sorting to meet various grading needs.1-12 level Customizable

Accurate

±2 g precision, 99.5% accuracy.

Efficient

45 birds/min, three times more efficient than manual labor and a 60% reduction in labor requirements.

Challenge

The processor encountered several obstacles. Manual classification of turkeys by weight was prone to error, resulting in inconsistent product categories and customer complaints. The throughput of the manual system averaged only 15 birds per minute, creating bottlenecks during peak demand seasons. Rising labor costs and reliance on seasonal workers further reduced efficiency. At the same time, international buyers required precise traceability and hygienic compliance, which the existing workflow could not guarantee.

weight sorter's Weighing display control module

Solution

SameGram introduced its Explosion-Proof 6-Level Checkweigher and Sorting System, engineered specifically for demanding poultry environments. The system offered six distinct weight categories, allowing flexible grading of turkeys according to the client's exact specifications.

One by one, the turkeys pass through the different levels of the conveyor belt of the sorting scale

Dynamic weighing ensured high accuracy, with precision maintained at ±2 g despite variable product sizes. The explosion-proof design enhanced workplace safety, while the modular structure allowed the system to be seamlessly integrated into the existing line. The user interface provided real-time monitoring, automatic compensation for moisture variation, and full connectivity with the client's ERP system.

Results

The upgrade transformed the production process. Sorting speed increased to 45 birds per minute, tripling the previous manual throughput. Classification accuracy rose to over 99.5%, ensuring consistent product quality across all six weight categories. Labor requirements were reduced by 60%, and data traceability gave the client confidence in meeting international compliance standards.

"By introducing SameGram's dynamic checkweighing systems into our packaging lines, we have been able to achieve a much higher level of consistency and efficiency. Beyond simply keeping pace with our fast-moving production, the real advantage lies in reducing product giveaway and ensuring every pack meets the exact specification. For us, this step is not just about short-term gains, but about aligning with the long-term trend toward precision and compliance in the global food market."

"SameGram's team provided comprehensive support throughout the installation," recalls Mr. Larsen, Production Manager. "They came well-prepared, addressed our challenges with expertise, and made sure the transition went smoothly. After more than a year in operation, I can say their systems are both durable and dependable—downtime has been kept to an absolute minimum. The dedication of our staff, combined with SameGram's technology, has transformed what used to be a labor-intensive process into one of the most modern lines in our industry."

"With the 6-level checkweigher, daily operations became smoother. Sorting is faster and more consistent, and downtime is rare compared to what we faced before."

– Peterson, Operations Director