Who cares about yield? Salmon processors making every gram count

The strength of a digital backbone

The digital foundation of the Salmon Filleting Solution transforms real-time and historical data into actionable insights. It seamlessly integrates with machines in both fully automated lines and more simple setups to track metrics like yield, throughput, trimming performance and equipment status. With this crucial insight, processors can make smarter decisions across filleting processes and dramatically shift production results.

• Gain production insight in real-time
• Improve consistency in product quality
• Reduce yield loss
• Maintain compliance with evolving regulations

"Every gram counts,” Parrish states. “With differing fish sizes, operator trimming styles, along with throughput bottlenecks, there are countless variables that impact yield and traceability. Processors need food processing software that turns that complexity into clarity.”

Real-world results

At Lerøy Midt, one of the world’s most advanced salmon processing facilities, five filleting lines are powered by JBT Marel Software. “If we compete with the lower‑cost countries, we have to automate the production and reduce the number of people in the lines,” explains Pål Kleven, Production Director at Lerøy Midt. “If not, we can’t compete. We have to be in the first line to develop new technology together with the suppliers.”

When Chilean processor Salmones Camanchaca SA upgraded their processing facility integrating software with high levels of automation they saw gains which reflected the adoption. “We invested in a Marel filleting line to improve our processing results. We have experienced an improvement of around 30% in productivity since the installation, with at least a 1% gain in yield,” explains Jorge Fernández, CEO at Camanchaca.

Advanced production control for yield optimization

When 1% improvement in yield can equal hundreds of thousands of dollars, optimization is about understanding and managing every component of each salmon, not just the fillet. The Salmon Filleting Solution achieves this by integrating with advanced equipment such as the Salmon Deheader MS 3028, the Filleting Machine MS 2730 and the Filleting Machine MS 2750. The machines automatically adjust to fish sizes and ensure cutting accuracy, while the software extracts data to drive optimization.

Key capabilities:

• Real-time process monitoring
• Precision fillet weighing
• Byproduct weighting
• Line throughput monitoring
• Yield percentage tracking
• Instant alerts for deviations

Quality control that sees everything

The digital eyes of the QC Scanner transform how fillets are evaluated and sorted. High-resolution imaging detects everything from melanin and blood spots to trimming defects, brown meat or left over skin, at millisecond speed, sorting fillets for rework.

The system stores and logs images, simplifying quality tracking with suppliers across the seafood supply chain.

Traceability, connecting the dots

As regulatory requirements become more stringent, and consumers demand more transparency on salmon origins, the ability to document every aspect of the filleting process has become essential. The Salmon Filleting Solution incorporates traceability software to create a comprehensive digital record that follows fillets from whole fish to final packaging, to support increasingly specific traceability compliance requirements and simplify audits. Smaller operations who use minimal automation are equally supported with audit-ready batch-tracking.

“You get auditors that know of Marel, and straight off the bat, that puts them at ease. If someone gives you a barcode and four hours to do a trace, you can have it done within about three or four minutes.” Enoch Robinson, Technical Manager at JK Thomson.

Processors can easily generate reports showing the movements of each fish throughout the filleting process, including quality control checks and any interventions required. If issues are detected in end products, the system enables fast, pinpoint recalls and assess if other batches processed at the same time have been affected. Food safety is improved and brand reputations protected.

Another advantage of using software in product tracking is it makes meeting labelling requirements easy. Accurate, order specific product data is automatically assigned to individual products.

Empowering the human element in advanced filleting

Attracting and retaining skilled workers is challenging. Technology helps shift roles from repetitive and manual to offer more appealing career paths for younger generations entering the workforce. Supervisors have access to real-time insights that help them onboard, train and promote staff. Even if staff turnover is high, technology ensures greater accuracy, consistency and food safety in end products, which ultimately boosts brand recognition and profits.

The future of salmon filleting

“We’ve used artificial intelligence (AI) in production and in the future, I think there will be more. Operators will only monitor the production, not handle product manually,” Børge Holm, General Manager Holmøy predicts.

The revolution in salmon filleting represents not just an evolution in how fish are cut, but a transformation in how processors approach this critical stage of operations. By placing data at the center of decision making and leveraging automation to ensure greater precision and control, forward-thinking processors are achieving filleting performance levels that were previously impossible. 

 “When you enter into a partnership like this with JBT Marel, it’s a commitment that goes both ways. We are absolutely certain we will work well and work purposefully to develop the industry over the next ten years together,” Børge Holm, General Manager Holmøy.

If you’re ready to get the advantages of digital Salmon Filleting, our experts are ready to tailor a digital strategy to your specific needs.