[Reverse Engineering Use Case] Success Story: Optimizing Production Lines with 3D Printing and Scanning at a Meat Processing Manufacturer

[3D Printing + Scanning Case Study] Successful Implementation - Meat Processing Manufacturer Optimizes Production Line with 3D Printing

Since 2003, Gourmet Cazorla has been manufacturing processed meat products and meat pastes. Their factory in Linares, Jaén, Spain, produces over 150 different flavors of meat paste.

Over the years, the company's production volume has continued to increase. Starting in 2022, they began exploring ways to optimize their production line using 3D printing technology. By introducing Ultimaker 3D printers and SHINING 3D scanners, Gourmet Cazorla has not only improved production efficiency but also succeeded in reducing both time and costs.

[Challenge] - Manufacturing Custom Replacement Parts

Having started as a small meat processing plant, the company previously outsourced the manufacturing of replacement parts to external suppliers. However, this involved long lead times, required significant labor and expense, and forced production line shutdowns, placing a heavy burden on employees with each occurrence.

By focusing on the potential of 3D printing technology, the engineering department became able to design new parts that lead to process improvements.Furthermore, they gained the opportunity to create original designs.
"We are constantly coming up with new replacement parts that we can use in production. Since we can reduce time and costs, the investment in 3D printing technology was recouped quickly. We plan to continue utilizing this technology in our factory," said Juan Alberto Marín, Maintenance Manager at Gourmet Cazorla.


[Solution] - Reverse Engineering with FDM 3D Printers and 3D Scanners


The company consulted with 3D printing experts at Sicnova regarding the solutions needed for their meat paste production line.First, they introduced an Ultimaker S5 3D printer and began incorporating rapid prototyping. Later, they also introduced a SHINING 3D EinScan SP scanner to digitize small, complex parts, allowing them to use them flexibly whenever needed.
 

Ultimaker S5 3D printer users can add the optional Ultimaker S5 Air Manager. It helps prevent exposure to unseen risks and keeps the work environment safer.

SHINING 3D EinScan SP scanner supports automatic scanning using a turntable, and manual scanning using a tripod is also possible.

Gourmet Cazorla explained their production needs to Sicnova. Sicnova not only introduced the technology but also designed samples to prototype parts for the production line. Since then, the meat processing plant has been using nylon to manufacture custom parts and replacement parts for their production line. They also use PLA when they want to keep costs down.

[Results] 90% Cost Reduction for Lid Fixures, Faster Production of Replacement Parts

After adopting digital manufacturing technology, Gourmet Cazorla became able to 3D print lid fixtures (the clamp parts used to secure jar lids) and feed combs for conveyor belts in-house. They also produce parts and lids for their own equipment.

                                      
                                                               Lid Fixtures and other parts                                                                                 Feed Combs
 

Compared to conventional parts, 3D printing the lid fixtures for the meat paste containers reduced costs by 90%. Previously, they ordered parts from a manufacturer at a cost of 1,000 euros per unit with a 20-day lead time. Now, they can produce the replacement part in just three days. The company is currently exploring other 3D printing applications, such as handrails and guide rails for the production line.

For Juan Alberto Marín and his team, 3D printing and 3D scanning have become indispensable technologies for Gourmet Cazorla. Mr. Marín stated, "Since we were able to reduce time and costs, this investment was recouped quickly. We will continue to use it in many more projects."

*Video provided by: Ultimaker partner Sicnova