16.04.2026

Labor shortage in the meat industry - when systems think for themselves

When production space is limited, hygiene regulations are stringent, and installation windows are tight, standard solutions reach their limits. For a client in Austria, the system provider VETEC ANLAGENBAU therefore developed the AEROMAT ^HYBRID, an innovative concept that combines multiple thermal treatments - including intensive cooling - into a single system, thereby opening up new possibilities in terms of infrastructure, product quality, and process efficiency.

When new capacity needs to be added to existing facilities, the available space often dictates the technology used. This was precisely the starting point for a special project in which VETEC ANLAGENBAU was tasked with replacing existing third-party equipment for an Austrian food manufacturer while simultaneously implementing significantly expanded process functionality. The challenges: The 19th-century building was severely constrained in terms of space; the renovation had to be carried out largely while operations continued; and, in addition, intensive cooling had to be implemented in areas where traditional hot smoking and cooking had previously taken place.

What was needed, therefore, was a systematic approach that took the actual on-site conditions into account: limited width, complex structural conditions, new requirements for product separation regarding low-care and high-care areas, and a short window for the conversion. Given the year-end business cycle, the deadline for commissioning in November 2025 had to be strictly adhered to, as available production capacity dropped to as low as 20 percent at times during the renovation phase. At the same time, new floors and load-bearing pillars had to be installed, interfaces and various systems for steam, cooling, electricity, and drainage had to be coordinated, and additional technical equipment had to be integrated into the building on multiple levels.

From Space Constraints to Product Innovation

The AEROMAT ^HYBRID was developed in response to this complex situation. The term “hybrid” describes the combination of two previously separate process worlds: classic hot-smoking treatment involving reddening, drying, smoking, and cooking on the one hand, and the switch to integrated intensive cooling on the other. Special care is also taken to ensure that the cooler does not become contaminated during the smoking process.

While products are typically discharged, rinsed, and then further processed in separate cooling stages after the thermal process, here the goods remain in the same system for the entire process. “Especially in cramped production environments, it’s not enough to simply build proven technology in a more compact form,” explains Andreas Sauer, Sales Director at VETEC ANLAGENBAU. “The key is that all process steps ultimately remain reproducible, hygienically safe, and maintainable even under these conditions.”

The benefits are clear: separate showering and cooling stations are eliminated to save space, manual transport between individual stations is reduced, and cooling occurs faster and in a more controlled manner than in a cold room. This is relevant not only for logistical reasons. Above all, the critical temperature range must be rapidly lowered after thermal treatment to ensure shelf life and product hygiene. The system design with integrated intensive cooling also takes this aspect into account.

Vertical Installation and Innovative Airflow Design

Da eine solch schmale Anlageninfrastruktur im bisherigen Portfolio nicht vorgesehen war, mussten kreative Lösungen her. Auf engstem Raum wurden daher fünf AEROMAT ^HYBRID Anlagensysteme über unterschiedliche Stockwerke hinweg und damit in die Höhe installiert – inklusive aller Maschinenaggregate, Rohrleitungen und Energiezuleitungen sowie Zubehör von Raucherzeuger über automatische Ascheentsorgung bis hin zur Reinigungspumpentechnik.

Since such a narrow system infrastructure was not previously included in the portfolio, creative solutions were required. Consequently, five AEROMAT ^HYBRID systems were installed across multiple floors in a very confined space - including all machine units, piping, and power lines, as well as accessories ranging from smoke generators and automatic ash removal to cleaning pump technology.

The reduced system width significantly increased the demand on the airflow. This is because the narrower the space between the trolley and the chamber wall, the greater the risk that products in the edge areas will over-dry or be treated unevenly. The system provider responded by completely redesigning the airflow technology: The nozzles were specifically developed to make better use of the Coandă effect. AI-supported flow simulations were used in the design. In addition, a new concept was introduced for the dynamic air roller: Instead of a traditional flap system, fans equipped with frequency converters operate on both sides of the chamber in alternating mode, allowing them to be optimally adjusted to the process and the product depending on the system’s load. This allows the air curtain to be controlled much more precisely, ensuring targeted airflow to every area of the trolley. “The goal was an airflow pattern that treats every product on the trolley under comparable conditions,” explains Andreas Sauer. “Only then process time, product yield and quality can be optimized at the same time.”

In addition to the actual process control, flue gas treatment also played a crucial role. For this purpose, the ECO ^{AIRCLEAN F} biofilter developed by VETEC is used. Within a filter bed filled with moistened wood chips, the smoke constituents are microbiologically broken down and converted into clean exhaust air.

The advantage: this process requires no additional primary energy. While thermal afterburning systems consume considerable amounts of energy, the biofilter only requires electrical drive energy for ventilation. The moisture content necessary for the degradation process is monitored by a sensitive measurement system. In this way, emissions are reduced to meet legal requirements, while the biofilter simultaneously contributes to the overall energy efficiency of the operation of installation systems.

Additional Features: Auxiliary Heating and Transit Logistics

As part of the special project, a total of five hot-smoking systems were installed, each designed for six trolleys. These include two hybrid variants positioned on the outer sides to ensure optimal maintenance access and to accommodate relatively small-caliber products such as Vienna sausages, frankfurters, bratwurst, ham, or bacon.

Two of the AEROMAT systems were also equipped with auxiliary heating to meet higher temperature requirements of approximately 130°C - particularly necessary for products such as German meat loaf (Leberkäse).

Furthermore, the system was already designed to support a transit function - loaded from the front and unloaded from the rear - in order to enable a clear separation of low-care and high-care products in the future. This decision was also made during the ongoing project and required structural adjustments under significant time pressure.

“Projects like these demonstrate that plant engineering today goes far beyond simply delivering a chamber,” emphasizes Andreas Sauer. “It involves integration into buildings, processes, media supply, hygiene zones, and future expansions.”

In line with this approach, VETEC also closely supported the technological commissioning phase. Master butchers from the company assisted with program configuration using real products, trained operating personnel, and, if required, supported fine-tuning during the initial weeks. In addition, remote support, on-site visits, and extended service packages remain available.

At the same time, the integrated MICROMAT ^ANALYZER control system enables seamless, IFS-compliant documentation of batches, temperature profiles, and all process parameters. For example, net weight is recorded in the system via barcode scanners and floor scales as products enter the system. This allows customers to optimize weight loss through test series with adjusted drying times - resulting in measurable cost savings while maintaining consistent product quality.

System Supplier VETEC: No Off-The-Shelf Technology

The AEROMAT ^HYBRID is not a universal solution for every production environment. Where sufficient space is available and separate hot-smoking and cooling zones can operate more economically, other concepts remain viable. Its full potential is realized in environments where limited space, high hygiene requirements, and flexible product programs converge
In such cases, spatial constraints become a technological advantage.

“For precisely these types of challenges, we as a system supplier do not develop off-the-shelf technology, but solutions designed around the product and the specific site,” summarizes Andreas Sauer.

When every meter counts in existing facilities, a system must do more than simply map processes - it must create space for efficiency and future growth.