AFD 2000 – Make Weigh Station

Problem: The red meat processing industry faces persistent challenges with traditional make weight stations, including inaccurate measurements, operational inefficiencies and high labour costs. These outdated systems struggle to integrate with advanced technologies like thermoformer machines (large-scale manufacturing machines that mold a sheet of plastic over an object while simultaneously vacuuming out the air), creating bottlenecks in modern processing workflows. Inaccuracies in weight measurements lead to significant financial losses through product giveaways and frequent manual interventions. Despite various attempts to replace or upgrade these systems, most off-the-shelf solutions fail to offer the seamless integration and industry-specific functionality required to optimise the make weight process. Solution: This project will design and develop an innovative make weight unit, called the AFD2000, which can be seamlessly integrated with modern thermoformer machines. This unit will streamline the weighing process by identifying each product’s weight category as correct, underweight or overweight and automatically directing it to the appropriate path. This reduces the need for manual handling and improves operational efficiency. A functional AFD2000 prototype will be built and pilot-tested with advanced sensors, automated controls and a modular design. Field trials and validation will inform refinement through performance data, user feedback and cost-benefit analysis. A comprehensive commercialisation plan will support large-scale manufacturing, industry partnerships and long-term adoption. Impact: By reducing product giveaways and waste through enhanced weight measurement accuracy, the AFD2000 will improve processing precision, efficiency, and overall profitability. Its seamless integration with thermoformer machines like the Multivac Thermoformer R145 and modern equipment ensures broad applicability across processing environments. The unit will also minimise manual handling, streamline operations and support consistent product quality. These benefits offer strong economic justification, enabling annual cost savings of up to $500,000 per facility. The AFD2000 has the potential to strengthen the competitiveness and profitability of red meat processors, transforming the industry's approach to make weight management.