Meat And Fish UPM Conveyor

UPM Meat & Fish Conveyor System – 3-Month Return on Investment

At Prolift Handling, we supply UPM conveyor systems to customers throughout Ireland, helping different Industries in reducing manual handling and meeting demanding hygiene standards. This international case study, from one of UPM’s long-standing customers, shows how a bespoke 360° meat and fish conveyor achieved a payback period of approximately three months – and demonstrates what is possible for Irish processors facing similar challenges.

The project involved the design and installation of a stainless steel, food-approved 360° conveyor system for a premium poultry producer. By replacing labour-intensive manual handling with a carefully engineered conveyor layout, the customer achieved faster processing, lower labour costs and improved hygiene, while maintaining the highest standards of food safety and product presentation.

While this installation was delivered directly by UPM in the UK, Prolift Handling provides the same technology, local support and after-sales service to customers in the Irish meat and seafood sector. If you operate a processing plant in Ireland, this case study gives a useful benchmark for the potential benefits of a UPM conveyor solution.

Customer background – premium poultry producer under pressure to increase capacity

The end customer is an award-winning free-range poultry producer with a long heritage in farming and a strong brand reputation in their home market. Since the mid-20th century they have specialised in rearing turkeys and geese to high welfare standards, supplying retailers, butchers and direct customers who expect consistent quality and traceability.

In recent years, demand for poultry has grown significantly as consumers look for year-round alternatives to red meat and seek out leaner protein options. At the same time, the customer was facing the familiar pressures that many Irish and UK processors will recognise:

• Ongoing labour shortages and difficulty recruiting skilled staff for physically demanding roles.
• Rising wage costs, particularly for seasonal production peaks.
• Stricter hygiene and food safety expectations from auditors, retailers and end consumers.
• Limited floor space, making it challenging to add more people or equipment to the existing line.
• A need to protect long-standing product quality and presentation standards while increasing output.

The company was still relying heavily on manual handling and movement of birds between different workstations. While the existing system produced good results, it was increasingly labour-intensive and difficult to scale. Management began looking for a way to automate the “dressing” and preparation process without compromising product quality.

The challenge – reduce manual handling while improving efficiency and hygiene

In the original set-up, operatives had to move poultry from one point on the line to another as different stages of processing were completed. This constant lifting, carrying and repositioning created a number of issues:

• High labour requirement per bird processed.
• Repetitive manual tasks with associated ergonomic and health and safety concerns.
• Unnecessary handling of product, increasing the risk of contamination.
• Difficulty maintaining a smooth, continuous flow through the work area.
• Space being taken up by ad-hoc trolleys and tables to support the process.

The business wanted to maintain the craftsmanship and attention to detail that their brand was known for, but with a more structured and automated way of presenting product to each operator. They approached UPM Conveyors to engineer a bespoke solution that would:

• Cut the number of manual movements required per bird.
• Allow staff to work in a more ergonomic, efficient way.
• Improve hygiene control and make cleaning faster and more thorough.
• Fit within the existing building and services, without a full factory redesign.
• Deliver a strong, measurable return on investment in a short timeframe.

The UPM conveyor solution – a 360° stainless steel meat and fish conveyor

Drawing on their specialist experience in food-approved conveyor systems, UPM designed, manufactured and installed a 360° stainless steel conveyor that encircles the central work area. Instead of product travelling in a straight line from one end of the room to the other, the new layout creates a continuous loop around the operators.

The key features of the solution include:

• 360° conveyor layout: The conveyor forms a full circle around the processing area, ensuring birds can be presented to each station in sequence without being lifted or carried across the room.
• Food-grade construction: All main components are fabricated from stainless steel with smooth welds and minimal horizontal ledges, making the system suitable for raw poultry and other meat or fish products.
• Microbiological and metal-detectable belt: The selected belt type complies with strict food industry requirements and supports HACCP-based control systems, helping to protect against foreign body contamination.
• Open, hygienic design: The conveyor is designed for regular high-pressure washdown, with easy access to internal components so cleaning teams can work quickly and effectively.
• Bespoke configuration: Belt height, speed and transfer points were tailored to the customer’s existing equipment, work methods and staff, making the solution practical from day one.

Because the system was engineered specifically for the customer’s process, it integrates cleanly with existing workflows and utilities. The result is a conveyor installation that supports, rather than disrupts, the way the team works – but with far less manual handling.

How the 360° conveyor works in practice

In operation, the new UPM conveyor effectively acts as a moving work platform. Birds are placed onto the belt at the start of the loop, then travel smoothly past each operator positioned around the circle. At each station, a specific task is completed before the product moves to the next person.

This arrangement offers several practical advantages:

• Operators no longer need to walk back and forth or carry product between stations.
• Work can be divided clearly by task, improving consistency and quality control.
• Supervisors can see the entire process at a glance, making it easier to spot bottlenecks or issues.
• The loop design encourages a smooth, continuous flow rather than stop-start handling.
• It is relatively straightforward to change belt speed or staffing levels to match seasonal demand.

For cleaning and maintenance, the open, 360° design gives excellent access. The belt and structure can be washed down quickly using high-pressure hoses, with minimal dismantling required. This reduces downtime between shifts and supports the hygiene standards required in modern meat and fish processing plants.

Results – strong labour savings and a 3-month payback

Following installation and commissioning, the poultry producer saw a significant reduction in labour requirements on the line. Fewer operators were needed to handle the same volume of product, and individuals were able to focus on their specific tasks rather than spending time moving items around the room.

According to UPM’s own assessment of the project, the cost of the conveyor system was recovered in roughly three months through labour savings alone. After that point, the customer continued to benefit from:

• Ongoing reduction in labour costs compared with the previous manual process.
• Improved ergonomics and a lower risk of handling-related injuries.
• Better process flow and more predictable line throughput.
• Enhanced hygiene control, supporting food safety audits and customer requirements.
• A robust, easy-to-clean conveyor asset with a long service life.

While every site is different, this installation demonstrates that a well-designed UPM conveyor system can deliver a very rapid payback where manual handling has previously been relied upon. It also highlights the value of working with conveyor specialists who understand the specific needs of meat and fish processing environments.

Designed for food safety and regulatory compliance

Food and drink manufacturers in Ireland operate under a rigorous regulatory framework, including requirements from the Food Safety Authority of Ireland (FSAI), EU hygiene regulations and retailer-specific standards. The design details of a conveyor system – from belt choice to weld finish – make a real difference to how easily those standards can be met day after day.

UPM’s meat and fish conveyors, such as the system in this case study, are designed from the outset with hygiene and compliance in mind:

• Use of stainless steel and food-compatible plastics throughout product contact areas.
• Open framework and minimal flat surfaces where debris or water could accumulate.
• Belts that are microbiological and metal detectable, supporting HACCP plans and foreign body controls.
• Layouts that allow visual inspection and cleaning access to all critical components.
• Compatibility with high-pressure washdown regimes and appropriate drainage.

For Irish processors, this means a conveyor solution that not only improves efficiency, but also supports hygiene audits, customer visits and retailer technical assessments.

What this means for Irish meat and seafood processors

The challenges faced by this poultry producer are very similar to those facing many Irish meat, fish and ready-meal manufacturers today: limited staff availability, rising input costs and the need to demonstrate best-in-class food safety. A bespoke UPM conveyor system, supplied and supported by Prolift Handling, can be a powerful way to address those pressures.

Whether you are processing poultry, beef, lamb, pork, smoked fish or value-added products, the principles remain the same:

• Reduce unnecessary manual handling and product movement.
• Create a smooth, predictable flow through each stage of the process.
• Make cleaning quicker and more effective between shifts and product runs.
• Design the system to suit your building, equipment and staff – not the other way round.
• Deliver a clear financial return on investment within an acceptable time frame.

As UPM’s partner in Ireland, Prolift can work with you from the earliest concept stage to explore whether a 360° conveyor or an alternative layout would best suit your plant and budget.

Typical applications for UPM meat and fish conveyors

UPM conveyor systems supplied by Prolift Handling can be configured for a wide range of applications in the meat, fish and prepared-foods sector, including:

• Poultry dressing and preparation (whole birds and portions).
• Meat trimming and inspection lines.
• Fish filleting, trimming and packing operations.
• Raw material transfer between cutting, marinating and packing areas.
• Chilling, cooling and buffering conveyors prior to packing.
• Metal detector, checkweigher and box-filling integrations.

Each system is designed using 3D CAD to match your process steps, floor space, utilities and hygiene regime. Where required, conveyors can also be integrated with weighing, counting or box-filling equipment for a complete handling solution.

Working with Prolift Handling as your UPM conveyor partner in Ireland

Prolift Handling is UPM’s supplier in Ireland, providing local expertise and support for customers who want to unlock the benefits of automated conveying in their processing lines. A typical project journey includes:

• Initial discussion and site survey: Understanding your products, throughput targets and existing layout.
• Concept design and proposal: Sketch layouts and outline specifications, with an initial indication of potential labour and efficiency savings.
• Detailed engineering: 3D CAD design of the conveyor system, including interfaces with your existing equipment.
• Manufacture and factory testing: Production of the stainless steel conveyor, controls and ancillary equipment.
• Installation and commissioning: On-site installation coordinated with your production schedule, plus full commissioning and hand-over.
• Training and after-sales support: Operator training, maintenance guidance and ongoing service support from the Prolift team.

Our goal is to provide a robust, hygienic conveyor solution that fits your process and delivers measurable results – just as in the case study highlighted here.

Is a 360° meat & fish conveyor right for your plant?

A full 360° conveyor system is not the only option, but it can be a highly effective choice where:

• You have several operators performing sequential tasks on the same product.
• Space is limited and you need to use every square metre efficiently.
• Existing processes involve a lot of carrying or repositioning product by hand.
• Hygiene standards are high and cleaning must be quick but thorough.
• You are aiming for a fast return on investment from reduced labour costs.

If your process is more linear or involves large equipment such as tumblers, mixers or ovens, UPM and Prolift can also design straight, inclined or modular conveyor lines that link these stages together while maintaining product integrity and hygiene.

Talk to Prolift about UPM conveyors

This case study shows how a well-engineered UPM Conveyor system can pay for itself in a matter of months, while also lifting standards of hygiene, safety and throughput. Prolift Handling brings that same technology and expertise to Irish producers, backed by local engineering support and a full range of lifting and material-handling solutions for your site.

If you would like to explore what a UPM conveyor system could do for your plant, we would be happy to review your current set-up and discuss potential options and payback

Interested in improving your meat or fish processing line?

Call our team on 01 458 4836 or email websales@prolift.ie to arrange a site visit or discuss your project.