Yield loss in pork processing: where it happens and how to catch it
Pork operations can lose product at several points between the carcass and the box. Because of their high volumes, many only find the loss at month-end. Arthur Carruthers, Client Success Advisor at Matrix Software, explains where the product goes and how processors can see the loss sooner.
How one pork operation found its missing product
One pork operation Carruthers worked with compared its total slaughter weight with the weight captured as input for deboning. Those two figures didn’t match.
The team then started measuring the weight received from the supplier or the slaughter process. They also tracked how long carcasses spent in the chiller before reaching the correct temperature for dispatch or deboning.
This showed that some carcasses were kept in the chillers for too long, and the extra time caused excessive drip loss.
Where pork processors lose product between the carcass and the box
According to Carruthers, these are common sources of loss:
● Carcasses lose weight through drip loss.
● Product is discarded as waste.
● Deboners accidentally drop product which gets condemned and transferred into the waste area.
● Inexperienced employees debone carcasses incorrectly or fail to meet the required specifications.
● Production doesn’t follow recipes correctly.
● The operation can’t track the exact quantity of stock used in production.
Classification is another risk. “High-value cuts deboned incorrectly can sometimes easily end up being cut into trimmings – check the yields” says Carruthers.
Why many processors only find yield loss at month-end
“Many pork processing operations handle such high volumes that daily or even weekly stocktakes are not practical,” says Carruthers.
This makes a system with strict controls and processes essential. It should include controls such as:
● Products should not be captured into an area without a corresponding stock transfer.
● Production recipes should require barcodes, so that stock received is accurately tracked and consumed.
How tracking yield per batch improves cost accuracy
Recipes calculate the cost per kilogram from the standards configured in the system. When yield is tracked batch by batch, any deviation from those standards becomes visible.
“By monitoring yield per batch, management can identify deviations and make informed decisions immediately,” says Carruthers.
In his example, a recipe might allow for a 12% weight loss during cooking, but actual production might show a 15% loss. Knowing this, the processor can review and adjust the recipe standard. Costing becomes more accurate, and the processor gets a clearer picture of what the product costs.
What one processor changed once it could see its yield
The processor Carruthers describes made three changes:
● It adjusted its recipe standards to better reflect actual production results.
● Management reviewed deboning yields against the expected cutting yields.
● Monitoring the quantity of trimmings also helped the processor identify potential issues on the production floor.
Management gained better visibility of production performance, and the figures highlighted areas that needed investigation.
How quickly Matrix measures yield loss
According to Carruthers, Matrix Software’s meat processing software can measure the losses he describes. These include drip and hang loss, cooking loss, recipe yields and block test yields that differ from established standards.
How soon you see the results depends on the type of loss:
● Recipe and block test results are ready as soon as the batch has been completed and processed.
● You can review hang and drip loss within about 24 hours, once the carcasses reach the required temperature for sale or deboning.
How to compare carcass weight with packed weight without a system in place
“A simple starting point is to use Excel to record the incoming carcass weight and the total weight of all finished boxes produced,” says Carruthers.
Once you have both figures:
1. Subtract the total box weight from the carcass weight to find the weight difference.
2. Divide the weight difference by the carcass weight and multiply by 100 to get the percentage difference.
Frequently asked questions
Where do pork processors lose product?
Common sources include drip loss in the chiller and product discarded as waste. Deboning mistakes and recipes that production doesn’t follow add to the loss.
How do I calculate yield loss as a percentage?
Subtract the weight of finished boxes from the incoming carcass weight to find the weight difference. Divide the weight difference by the carcass weight and multiply by 100 to get the percentage difference.
How can pork processors catch yield loss before month-end?
Track yield per batch so you can spot deviations from your standards as soon as a batch is complete. Strict stock controls also help, such as requiring a stock transfer before product moves into an area and barcodes on production recipes.
Find out where your operation loses yield
Matrix can track yield per batch and measure losses such as drip and hang loss. To find out how this would work in your operation, speak to a Matrix meat processing specialist.
