Unlocking the Full Potential of Your DSI: Why the SMART Sorter Is the Essential Next Step for Poultry Processors
- Laitram Machinery
- Aug 7
- 3 min read
Updated: Aug 13
In the world of poultry processing, efficiency and quality are everything. For years, the DSI has set the standard as the go-to machine for the first leg of portioning, trusted by leading processors to deliver precise cuts and maximize yield. But what happens after the DSI does its job? For many plants, the answer is still manual harvesting (sorting)—a process that’s not only costly and inconsistent but also leaves significant value untapped.
If you’re a plant owner, manager, or decision-maker focused on optimization, it’s time to ask: Is relying on manual harvesting (sorting & inspection) after your DSI holding your operation back?
The Hidden Costs of Manual Sorting
Let’s start with the reality on the ground. After the DSI portions whole nuggets and breast filets, most processors still depend on teams of nugget or strip harvesters—often six or more per DSI—to sort products by hand. These employees are tasked with quickly evaluating size, shape, blood spots, and fat content as products speed by on a conveyor. It’s a tough job, and turnover is high.
The result? Labor costs soar, and the process is plagued by inconsistency and subjectivity.
Even with the best-trained staff, manual inspection and sorting is limited by human perception and fatigue. Recovery rates for in-spec nuggets and strips typically hover around 5%—meaning a huge portion of potential premium product is lost to further processing or trim, eroding your bottom line.
SMART Sorter: The Game-Changer Your DSI Needs
This is where the SMART Sorter comes in. Designed to integrate with your DSI seamlessly, the SMART Sorter uses advanced laser imaging, AI, and computer vision algorithms to inspect and sort chicken nuggets and breast strips with unmatched precision. It’s not just automation for automation’s sake—it’s a strategic upgrade that directly addresses the pain points of manual harvesting (sorting).
With the SMART Sorter, you can expect:
Dramatically Improved Recovery Rates: Plants using the SMART Sorter have seen recovery rates jump from 5% to between 15% and 25%. That’s a significant increase in premium product, directly boosting your revenue.
Consistent, Objective Quality Control: The SMART Sorter removes the subjectivity of human inspection, ensuring every piece is evaluated against your exact specifications for size, shape, fat, and appearance.
Reduced Labor Costs and Turnover: By automating the sorting process, you can redeploy staff to higher-value tasks, reduce reliance on hard-to-fill positions, and lower overall labor costs.
Scalable, Repeatable Results: The SMART Sorter makes your QC process repeatable and scalable, supporting growth and operational excellence.
Data-driven decisions
Seamless Integration, Rapid ROI
Worried about complexity? Don’t be. The SMART Sorter is designed for seamless integration—trim from the DSI is easily transferred via totes or conveyors, and the system fits naturally into your existing workflow. Most importantly, plants that have implemented the SMART Sorter have seen a return on investment within the first year, making it a smart financial decision as well as an operational one.
The New Standard for Poultry Processing
In today’s competitive market, every percentage point of yield and every dollar of labor savings counts. The DSI 800 is an industry leader for a reason—but stopping there means leaving value on the table. The SMART Sorter is the essential next step, transforming your portioning line into a model of efficiency, consistency, and profitability.
Don’t let your DSI work alone. Make the SMART Sorter your new standard for whole nugget and breast filet sorting—and unlock the full potential of your operation.
Ready to see the difference for yourself? Contact us today to learn more, request a demo, or speak with our team about how the SMART Sorter can transform your plant’s performance.
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