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QDSnacks®

The Future of meat Snacks today

Nº4 | Year 2016 | From 7 to 12 may ENG

MOVISTICK TRIPLEX 3 Heads for Exponential Injection

CooklineMatrix

GOURMEATMETALQUIMIA and Haute Cuisine

www.metalquimia.com @MetalquimiaNews

Cooking 4.0 at a single click

2 | IFFA Special Edition

Surely there is no technology more vital to ensuring the survival of our species, while eliminating growing social inequalities, than our ability to cultivate and make grow more and new food. In a scenario of climate change, rising temperatures, changes in rainfall, extreme weather, etc. ... being able to adequately feed a growing world population (10 billion people by the year 2050) with a growing consumption of meat protein on a global scale, presents us with a great challenge that puts a lot of pressure on those of us who are dedicated to the food industry in general, and the meat industry in particular.

More specifically, it is estimated that in a few years the world will have to produce 70% more food to feed an exponential demand for diets rich in protein and, therefore, the big moves that will have to be undertaken by the global meat industry should go in this direction: to ensure the supply of scarce protein within a context of exponential consumption.

Faced with this Great Challenge, there is only one way out: to be proactive and invest all our resources in the innovations that will allow us to duplicate the Earth’s food yield, together with the launching of new technologies, that allow us to EXTEND THE PROTEIN, REDUCE ITS REJECTION and EQUITABLY DISTRIBUTE ITS CONSUMPTION, key factors for feeding abundantly and safely a planet where resources are increasingly scarce.

It is with this disruptive mentality that METALQUIMIA returns to IFFA 2016 with renewed ideas, presenting exponential technologies to provide solutions to these exciting challenges … technologies capable of reinventing processes, connecting facilities, proposing new products, generating new Business Models and, as we have done ever since our founding in 1971, aspiring to transform the way the world processes meat.

So let us show you, and share with you at our Stand, a bit of the future that awaits us… Good IFFA to all!!

Josep LagaresExecutive President of METALQUIMIA

EXPONENTIAL IFFA

editorial

IFFA Special Edition | 3

In the first half of 2014, METALQUIMIA closed an agreement with the Chinese food group WH Group (formerly Shuanghui International / Luohe Shuanghui Imp and Exp) for supplying one of the most modern processing plants for cooked meat products in the world. The plant, located in Shanghai, has a production capacity of 100 tons of product a day and will be fully operational by the end of 2016. At the beginning of 2016, METALQUIMIA was also chosen as one of the main suppliers of the processing lines at the new factory of Campofrio Food Group in Burgos (Spain). The new CFG plant will incorporate the latest technologies of automation and intelligence for the manufacture of cooked whole-muscle meat products, thus becoming one of the processing leaders of Southern Europe. In addition to the above-mentioned projects, METALQUIMIA has also supplied the fully automatic macro-facilities of ELPOZO (Spain), CASA TARRADELLAS (Spain), AURORA (Brazil), CASTROLANDA (Brazil), FRIMESA (Brazil) or SEARA-JBS (Brazil), among many others… all pioneer plants that are operating with the most advanced meat-processing equipment and technology worldwide. As well as the integral solutions and turnkey plants, these global leaders have also given very high ratings to METALQUIMIA’s technological assistance, with an option that brings together cutting-edge technology, the highest degree of automation and technological know-how, guaranteeing top quality of the finished meat product in the global market.

According to Josep Lagares, CEO of Metalquimia: “Being awarded these mega-projects consolidates our reputation as preferred suppliers of large multinationals for the installation of fully automatic plants for the manufacture of meat products. There is no other supplier in the world who can offer an automatic turnkey plant with all the machinery required for the entire process, from preparation of the meat to final packaging, and which includes, in the same package, robotics, artificial intelligence and the meat-processing technologies of the future.” In the photo, Mr. Wan Long, President of WH Group, and Josep Lagares, CEO of Metalquimia

AUTOLINESThe global leaders choose METALQUIMIA


METALQUIMIA introduces at IFFA 2016, for the first time in its history, the MOVISTICK TRIPLEX…. the self-piloted hydraulic injector that incorporates up to 3 injection heads. This is, without a doubt, the injector for meat products (bone-in or boneless) with the highest injection potential in the global meat sector that, equipped with a triple hydraulic piston pump, provides the highest injection and productivity

rates on the market and the highest final yields with maximum precision, obtaining spectacular brine distribution and color uniformity, thus providing an answer to the demanding exponential challenges to be faced by the meat industry of the future, even surpassing the “mythic 150% injection” in a single pass, thereby eliminating the need to grind the meat to absorb such large quantities of brine.

TRIPLEX INJECTION TECHNOLOGY3 Heads for Exponential Injection

Smart Injection: version 4.0 designed for the cyber-

industry of the future.

Increased operating cycles = increased productivity.

Optimized separation between heads for differential

injection.

SPRAYPLUS® Technology for optimization of

distribution (optional).

Great simplicity of needle extraction for inspection,

cleaning and sanitation.

MOVIPLUS5500 v4.0A real PLUS in Injection Technology

Electro-Hydraulic Operation, controlled by PLC and

Display.

Selection of the injection process: Single or Twin Head.

Tenderizing head adjustable per cycle for maximum

protein extraction.

UP&DOWN System for skin-on products (optional).

Available in Boneless / Bone-In versions.

Totally cutting-edge design for optimal hygiene and

food safety.


Smart Tenderizing: version 4.0 designed for the cyber-industry of the future.Mechatronic Operation, controlled by PLC and Display.Automatic Fixing of Rollers for maximum protein extraction.Automatic Regulation of Separation between Rollers (from +50 mm to -20 mm).New ROLLERCOMB wipers ensure constant tenderization in real time.Significant Reduction in Massage times.Great Improvement in cooking and slicing yields. Minimization of defects in intermuscular binding.Reduction of Components for optimal maintenance.New Design for optimal hygiene and food safety.New Roller Extractor Device (optional).Completely adaptable to any existing injection line.Available in TWIN and SINGLE versions.

Total and safe cleaning and sanitation of needles.Increased injection quality and food safety. Drastic reduction in manpower costs.Fully automatic cleaning cycle. Maximum Capacity: 432 needles per cycle (720 needles in MULTIPLUS version).

METALQUIMIA displays at IFFA 2016 the NEEDLECLEAN, the machine for automatic and simultaneous cleaning and sanitation of all the injector needles. The NEEDLECLEAN, an excellent complement to ensure daily consistency of injection percentages and constant quality of the injected product.

AUTOGRINDTHE FILOGRIND TENDERIZER IN THE DIGITAL AGE

UNIVERSAL NEEDLECLEANERAUTOMATIC CLEANING AND SANITATION OF NEEDLES


MULTIPLUS 720HIGH-DENSITY SPRAY MARINATION METALQUIMIA introduces at IFFA 2016 the new MULTIPLUS 720 marinating line, especially recommended for marinating low-profile (chicken parts, bacon, etc…) and medium-profile (whole pieces of chicken) fresh meats, with a wide range of new features for optimal cost and functionality of the marinating line, providing greater injection precision, less dripping (greater retention), no needle marks, as well as higher quality and consistency of the fresh marinated product.

Fuerza (g)

tiempo (sec)

3250

3000

2750

2500

2250

2000

1750

1500

1250

1000

750

500

250

0

-250

0 2

3:T

2:T1:T1:F

The “Memory Effect” provides spectacular recovery of the needle.

High-Density and High-Precision Spray Marination: up to 2816 injection points.Minimal dripping: optimization of yield.Very High productivity, without market competition.Smart Marinating: version 4.0 designed for the cyber-industry of the future. Mechatronic Operation, controlled by PLC and Display.Automatic rammer control system (height / aperture) as per meat profile.Great simplicity of needle extraction for inspection, cleaning and sanitation.Totally cutting-edge design for optimal hygiene and food safety.

Needles with “Memory Effect”

Flexible “Memory Effect” needles with return to original position.Made of a special alloy that gives them maximum strength and durability.2 mm diameter prevents unwanted marks.Improved design for optimal marinade flow into the meat.


“TWO IN ONE”2-IN-1 = D-ICER x MARINATOR METALQUIMIA presents at IFFA 2016 the “2 in 1” machine, the dual function reactors for marinating and thawing that incorporate a very gentle massage system of great operational versatility, which provide for marinating and/or thawing very delicate meats with optimal quality of the fi nished product.

The MARINATOR feature is highly recommended for those marinating processes where marination by injection is not advisable due to the special characteristics of the raw material (size, fragility, etc. ...), providing for conditioning and/or marinating a large number of bone-in or boneless products made of pork, beef, poultry or seafood, demonstrating great effi ciency in processes of impregnation, coating (oils, aromas, spices, etc. ...), breading, smoking, rehydration and/or cryogenic freezing of meat products and food in general.

The D-ICER feature provides the meat processor with a considerable reduction in thawing times, reduced installation space, the possibility of modular growth, and improved thawing yields that result in very attractive Returns on Investment (from 6 to 10 months depending on the number of cycles /day).

METALQUIMIA presents at IFFA 2016 the “2 in 1” machine, the dual function reactors for marinating and thawing that incorporate a very gentle massage system of great operational versatility, which provide for marinating and/or thawing very delicate meats with optimal quality of the

feature is highly recommended for those marinating processes where marination by injection is not advisable due to the special characteristics of the raw material (size, fragility, etc. ...), providing for conditioning and/or marinating a large number of bone-in or boneless products made of pork, beef, poultry or seafood, demonstrating great effi ciency in processes of impregnation, coating (oils, aromas, spices, etc. ...), breading, smoking, rehydration and/or cryogenic freezing of meat

feature provides the meat processor with a considerable reduction in thawing times, reduced installation space, the possibility of modular growth, and improved thawing yields that result in very attractive Returns on Investment (from 6 to 10 months depending on the number

DRYBINDER NEW DRYBINDER: TUBULAR DRAINAGE

METALQUIMIA presents at IFFA 2016 the new TUBULAR DRYBINDER, the continuous drainage system for injected marinades that provides for obtaining optimal brine retention and a signifi cant improvement in quality of marinated meat products after packaging. Its specifi c design, its possibilities of automatic regulation of rotation speed and tilting angle, together with diverse confi gurations of

brushing accessories, make it the defi nitive drainage system for quick draining of superfi cial free brine, as well as providing a slightly greater retention of injected brine, thereby obtaining a drier product, resulting in increased yields, improved shelf-life (expiry) and optimal appearance of the product after packaging.

NEW DRYBINDER: TUBULAR DRAINAGENEW DRYBINDER: TUBULAR DRAINAGE

METALQUIMIA presents at IFFA 2016 the new TUBULAR , the continuous drainage system for injected marinades

that provides for obtaining optimal brine retention and a signifi cant

brushing accessories, make it the defi nitive drainage system for quick draining of superfi cial free brine, as well as providing a slightly greater retention of injected brine, thereby obtaining a


TURBOMEAT®

VERY HIGH-YIELD MASSAGE

TURBOMEAT® Process or Intensive Accelerated Massage, the gateway to Just-In-Time cooked products. TURBOMEAT® technology allows you to accelerate the massage and maturation process for cooked meat products, resulting in markedly shorter processing times (up to 50 % reduction in total massage time), without having to give up the versatility, the results (in consistency and binding) and the technological and organoleptic advantages of a conventional massaging drum.

The combined work of TURBOMEAT® Intensive Accelerated Massage technology together with TRIPLEX injection technology offers interesting synergies that greatly facilitate the absorption of free brine, thus preventing the formation of intermuscular exudate and making it possible to produce quality cooked whole-muscle products with very high yields (230-260%) that are very attractive to the consumer.

TURBOMEAT® technology in processes of short duration, with reduced maturation times, and above all aimed at the manufacture of meat products of medium, high and very high yield, can signifi cantly increase productivity while maintaining an integral appearance of whole muscle in the slice, an aspect that is highly valued by the consumer.



TWINVAC “EVOLUTION” “EXPERIENCE THE EXCELLENCE” IN STUFFING

METALQUIMIA presents at IFFA 2016 the new TWINVAC “EVOLUTION”, the “ALL-IN-ONE” whole muscle stuffer suitable for all types of meats, from emulsions to whole-muscle pieces, that provides for obtaining maximum compactation, the best weight precision, higher stuffing speed, resulting in a stuffed product of unsurpassed

quality, with a total absence of internal holes, and a perfect definition of muscle morphology. In addition, the “friendly” design of TWINVAC “EVOLUTION”, which occupies less floor space, allows for easy maintenance, cleaning and sanitation that is unrivalled in the sector.


COOKLINE MATRIX Cook & Chill 4.0 at a single click METALQUIMIA introduces at IFFA the cooking system of the future at a single click… the new COOKLINE MATRIX, which represents the latest in cooking / chilling systems for meat products, integrates the operations of molding, cooking, cooling and demolding in a versatile, matricial and fully robotic smart flow line. The exclusive operating system

of the COOKLINE MATRIX maximizes heat exchange, optimizing thermal efficiency of the process, providing an effective reduction in energy costs and a highly regular cooking / chilling process that results in a safer product of high organoleptic quality.


QDSnacks®

METALQUIMIA introduces at IFFA 2016 the QDSnacks® technology, an evolution of QDS Process® technology, an impressive quantum leap in the design and manufacture of protein-based snacks, which enables innovation and industrialization in the world of meat snacks in a way which, up until now and with existing technologies, has not been possible, offering multiple advantages and accelerated innovation options with respect to the rest of today’s processing alternatives.

The innovative QDSnacks® technology enables you to design different highly profitable meat snack options, thus meeting the challenge to satisfy a fast growing market demand.

QDSnacks® offers the consumer other types of food to eat between meals: food that is healthier, rich in protein, low in carbohydrates, free of trans fats … which, without a doubt, are already transforming the global food market.

DRY MEAT SNACKS (Jerky type)

EXTRUDED SNACKS (mini-salamis)

CRUNCHY SNACKS (Chips)

The Future of Meat Snacks Today Snack Area

“Much more than a snack”QDSnacks®


QDS Process®A step forward in the transformation of meat into value

QDS FACTS

QDS Process® technology is the result of years of cutting-edge Research and Development, whose success is based on a continuous digitalization system that applies traditional air drying to fermented slices instead of to whole pieces. This leads to a significant reduction in production time, going from a process of several weeks to a drying period of between 15 and 60 minutes. This reduction in production time is achieved without any alteration in the organoleptic and nutritional characteristics of the finished product, a fact that introduces a new processing paradigm that is giving rise to the emergence of new product ranges and new business models.

The drastic reduction of the drying process also means greatly increased productivity for processors, since it enables them to improve their financing and production costs, and react quickly to any market demand by bringing the process to just-in-time manufacturing and eliminating the need to maintain large stocks of in-progress or finished product. The QDS process also provides for a reduction in the floor space required for drying. Improved food safety, as well as a significant reduction in energy consumption and environmental impact are other important advantages of this innovative process.

Accelerated R&D process: design of high

added value new meat products.

Reduction in production costs: up to 10%.

Reduction in financing costs: less working capital.

Less space required: lower investment in assets.

Reduced energy bills: up to 40%.

Just-In-Time process: flexible short-term planning.

Digitalization of the slice: higher final yields.

Better food safety: elimination of drying risks.

New Business Models Generation.


CHANGES IN CORPORATE GOVERNANCE

It is in this sense that Mr. Narcís Lagares, founder and principal shareholder of the company since 1971, will now occupy the position of Honorary President of Metalquimia Group. Mr. Josep Lagares, who has been the General Manager since 1996 will become Executive President (CEO).

Mr. Llorenç Freixanet, who has profound knowledge of the company, in which he has worked since 1987 in all its professional areas and has served as Intelligence Director during the past 16 years, will become General Manager, taking over responsibility for the daily and operational management of the company.

Mr. Pere Canadell, who for the past 10 years has been Manager of Metalquimia’s Electronics and Software Department, with his many years of experience and expertise in Robotics, Automation and Smart Systems will become the Chief Coordinator of the Engineering Department, his former position to be occupied by Mr. Josep Tarradas, Electronics and Software Engineer who has served in the company for the past 10 years.

At the same time Mr. Ricard Vilà, who has done high-impact work within the Intelligence Department, will now assume responsibility for managing said department in order to continue providing Corporative

Josep Lagares, CEO of METALQUIMIA. Josep Lagares and Llorenç Freixanet.

Metalquimia has made a number of changes in its corporative governance, with the aim of propelling the Girona company toward a new business dimension while taking advantage of the new opportunities being opened up by a global meat sector experiencing rapid growth and evolution. The organizational changes have been based on the promotion of internal talent, the pillar on which this strategic shift pivots.

and Competitive Intelligence services to all organizational units within the company.

With these organizational changes, the Lagares family, which holds 100% ownership of METALQUIMIA, aims to strengthen its global leadership position, renewing its creative mechanisms to transform the way the world processes meat.

“This new corporative structure gives METALQUIMIA a renovated impulse to continue providing solutions and technologies that improve the competitiveness of the global food industry”, explained Josep Lagares, the new CEO of METALQUIMIA.

In reference to the new responsibility entrusted in him, Lagares said: “The Executive Presidency will allow me to focus even more fully on the future strategy of the business group, promoting the search for new products and new business models (Creativation), key points in the development of the company for the next 5-10 years, in order to meet the challenge of the exponential changes that are taking place within the global meat industry.“


TECHNOLOGY BOOK FOURTH EDITION!!!!

METALQUIMIA presents at IFFA 2016 the fourth edition of THE BOOK OF TECHNOLOGY ARTICLES, a book with a collection of articles on the most cutting-edge processes for the production of cooked & marinated meat products and QDS technology for the accelerated drying / curing of meat products. The new edition incorporates 4 new articles, as well as a complete selection of the latest advances and developments carried out by METALQUIMIA’s Technology Department, in conjunction with its strategic partners, that will undoubtedly contribute to improving and updating the technical know-how and technological expertise of specialists in the meat sector worldwide.

METALQUIMIA’s technology team presents at IFFA a real and virtual showcase of meat products, with the aim of showing a wide variety of fi rst-class products: cooked, smoked, cured, marinated and snack products. METALQUIMIA’s technology showcase at IFFA constitutes an authentic sample of the trends and evolution currently taking place in the global meat market.

PRODUCT SHOWCASE

TECHNOLOGY BOOK


The same CREATIVATION® that has nourished METALQUIMIA since its inception is what has always characterized our country and our people and, among many other things, has placed our gastronomy at the head of Global Haute Cuisine, making the Girona region the cradle of the world’s great Chefs … with the Roca brothers of El Celler de Can Roca and Ferran Adrià of El Bulli, as maximum exponents.

With this particular spirit of Curiosity, Creativity and Innovation that inspires us, METALQUMIA offers its customers around the world GOURMEAT, an innovative compendium of Haute Cuisine, the result of the best culinary ideas of our People and our Organization, and which transforms into top-quality gastronomic format the cooked and cured meat products that have been our passion ever since our beginnings.

From these lines we would like to thank the brothers Josep, Joan and Jordi Roca, of El Celler de Can Roca (World Best Restaurant 2015), for mentoring this book.

GOURMEAT by Metalquimia

Joan and Josep Roca (El Celler de Can Roca) with Josep Lagares.

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