Food Engineering May 2011

SPECIAL REPORT: SUSTAINABILITY SOFTWARE MONITORS ENERGY USAGE IN REAL TIME May 2011 |

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Sanitary Plant Design The New Meaning of Clean

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FEATURES COVER STORY

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Sanitary Plant Design: The New Meaning of Clean With industry attention riveted on improved food safety, sanitary design of plants is front and center.

51

Green Manufacturing: Software Tracks Sustainability Take action now to reduce consumption by monitoring energy usage in real time.

61

Conveying Systems Every process needs connectivity—the right “circulation system” to provide optimum hygiene, flexibility, fast changeovers and ease of maintenance at the lowest possible cost.

73

Tech Update: Motors & Drives Power transmission technology is in flux, and that adds up to a wealth of options for food and beverage manufacturers.

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42 DEPARTMENTS 8

Editor’s Note

10

Calendar of Events

13

Manufacturing News Shearer’s Foods accepts Plant of the Year Award

17

Food Packaging Always be continuous

23

Food Safety Simple, inexpensive methods to protect customers and your business

Connect with FE on Facebook

29

Focus on Valves and Weighing Equipment

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Join FE’s Group on LinkedIn Food Engineering Magazine

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Engineering R&D Gen II for biofuels

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FOOD ENGINEERING Volume 83, Issue 5 (ISSN 0193-323X) iis published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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www.foodengineeringmag.com NORTH AMERICA SALES Patrick Young Publisher & District Sales Manager 600 Willowbrook Lane, Suite 610 West Chester, PA 19382 [email protected] Tel: 610-436-4220, ext. 8520; Fax: 610-436-6277 Mid-Atlantic Territory: CT, Eastern PA, NJ, NYC and LI, VA, MD, DE, Washington DC Paul Kelly District Sales Manager 155 N. Pfingsten Rd., Suite 205 Deerfield, IL 60015 [email protected] Tel: 847-405-4048; Fax: 248-502-1017 Midwest and Northeast Territory: Northern IL, WI, MN, IA, KS, MO, SD, ND, CO, WY, NE, TX, OK, NM, AR, NH, VT, MA, RI, ME, Saskatchewan Brian Gronowski District Sales Manager 13973 Meadowlark Ln. Newbury, OH 44065 [email protected] Tel: 440-564-5732; Fax: 440-564-5734 Midwest and Southeast Territory: OH, IN, WV, KY, TN, MI, NY, Western PA, FL, GA, NC, SC, AL, Southern IL, MS, LA, Ontario, Quebec Wayne Wiggins Jr. District Sales Manager 454 Funston Avenue San Francisco, CA 94118 [email protected] Tel: 415-387-7784; Fax: 415-387-7855 West Coast Territory: AZ, CA, OR, WA, AK, UT, ID, HI, British Columbia Carolyn Dress Inside and Online Sales Manager Tel: 847-405-4046; [email protected] Suzanne Sarkesian Classified Sales Manager Tel: 248-786-1692; [email protected] INTERNATIONAL SALES Gabriele Fahlbusch IMP InterMedia Partners GmbH Tel: 49 (0)202-27169-15; Fax: 49 (0) 20227169 20 [email protected] Germany, Switzerland and Austria Fabio Potesta Mediapoint & Communications SRL Tel: 39-010-5704948; Fax: 39-010-5530088 [email protected] Italy CORPORATE DIRECTORS Publishing Timothy A. Fausch Publishing John R. Schrei Corporate Strategy Rita M. Foumia Marketing Ariane Claire Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Directories Nikki Smith Human Resources Marlene J. Witthoft Conferences & Events Emily Patten Clear Seas Research Beth A. Surowiec

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May 2011 | Food Engineering | www.foodengineeringmag.com

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EDITOR’S NOTE

Turn a missed opportunity into a manufacturing solution

A Joyce Fassl, Editor in Chief e-mail: [email protected]

s I’m writing this month’s Editor’s Note, I’m working in my office after just reviewing the evaluation forms from the Food Automation & Manufacturing Conference and Expo (FA&M) held in early April. Food Engineering has been developing conference programs for about 15 years, and while we typically get excellent reviews, I can’t recall another one in our history that’s been this well received. The reviews speak for themselves: • “The presentations are the best ever in quality” • “Best of the five to six I’ve attended” • “The conference was one of the most professionally run events I have attended” • “Great job as always” • “Best in class” and • “Excellent subjects, speakers and material.” You may be wondering why I’m tooting our own horn. The reason: Most of you reading this column weren’t there, and I wanted to let you know you’re missing out on a fantastic learning experience and outstanding networking opportunity.

Over the years, FA&M has become an essential event on the yearly calendar for food processors and suppliers alike. Its intimate size allows each attendee to meet every processor or supplier at the event, and the level of professionals attending are able to collaborate and achieve manufacturing solutions, whether they’re in attaining sustainability goals, improving food safety systems or gaining plant efficiency. I realize busy personal lives and hectic work schedules may preclude many people from attending. I can only urge you to plan now to consider joining us for FA&M 2012 at the Marriott Sanibel Harbour Resort, in Fort Myers, FL on April 22-25, 2012. We’ll be working over the summer to once again develop an outstanding program with the industry’s best and brightest speakers. Watch for 2012 program updates in future issues of Food Engineering, and visit our website, www.foodautomation.com, for video clips of past speakers and information about recent programs and expo participants. It’s well worth your time and investment. ❖

Food Engineering Editorial Advisory Board Tom Lance Vice President-Operations The Boston Beer Company Ed Delate Vice President, Global Engineering and Corporate Social Responsibility Keystone Foods LLC

8

David Watson Vice President-Engineering Campbell Soup Company International and Baking Technology Sam Casey Director of Engineering H. J. Heinz

May 2011 | Food Engineering | www.foodengineeringmag.com

Alex Peele Director of Project Engineering Interstate Brands Corp.

Dan Sileo Vice President, Manufacturing Sunny Delight Beverages

Diane Wolf Global Vice President, Safety and Environmental Sustainability Kraft Foods

David Haase Vice President of Operations WILD Flavors

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CALEN DAR JUNE 2011 June 8-10: 45th Annual Microwave Power Symposium; The Doubletree Hotel, New Orleans, LA; International Microwave Power Institute; www.impi.org/45th_IMPI_ Symposium.html 11-14: IFT11 Annual Meeting & Food Expo; New Orleans, LA; Institute of Food Technologists; 312-604-0238; www.ift.org 16-17: Workshop on Novel Sampling and Sensing for Improving Food Safety; GTRI Conference Center, Atlanta, GA; Food Processing Technology Division, Georgia Tech Research Institute; www.foodsensing.gatech.edu 21-23: PACKEX 2011; Toronto Congress Centre, Toronto, ON; Canon Communications; 289-971-0534; www.canontradeshows.com

SEPTEMBER 2011 11-14: ProcessTechnologyXchange; The Lodges at Deer Valley, Park City, UT; VerticalXchange; 952-736-9370; www.pt-xchange.com 19-21: International Dairy Show; Georgia World Congress Center, Atlanta, GA; International Dairy Foods Association; www.dairyshow.com 26-28: Pack Expo Las Vegas; Las Vegas Convention Center, Las Vegas, NV; Packaging Machinery Manufacturers Institute; 703-243-8555; www.packexpo.com

OCTOBER 2011 • Vertical Unit = Small Foot Print • (5) Times More Surface Area Than Conventional Equipment • Quick & Easy Maintenance and Inspection • Lowest Operating & Maintenance Costs • Test and Rental Units Available

2-4: All Things Baking; Renaissance Schaumburg Hotel and Convention Center, Schaumburg, IL; The Retail Bakers of America, American Bakers Association and Bakery Equipment Manufacturers & Allieds; www.allthingsbaking2011.com 5-6: Conventional and Advanced Continuous Flow Thermal Processing; NC State University, Raleigh, NC; 919-515-2957; www.ncsu.edu/project/foodengineer/ short-course 17-20: ISA Automation Week; Arthur R. Outlaw Mobile Convention Center, Mobile, AL; The International Society of Automation; 919-990-9206; www.isaautomationweek.org/2011

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1-4: PROCESS EXPO 2011; McCormick Place, Chicago, IL; Food Processing Suppliers Association; www.fpsa.org

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MANUFACTURING

`NEWS PLANT OPENINGS & EXPANSIONS First announced in FE October 2010, Leprino Foods’ new cheese factory in Greely, CO is under construction. The $270 million facility is being built on the former Western Sugar site and will occupy 847,000 sq. ft. The new Leprino site is expected to help the regional economy by as much as $1.8 billion, and increase regional dairy herds by 80,000 cows to provide the 8.2 million pounds of milk per day the plant will consume when it’s fully operational in 2013-2014.

Dean Foods is overhauling a vacant structure in Dallas. TX. The 280,000-sq.-ft. building is expected to cost $40 million to construct, and an additional $45 million is slated for equipment. The plant will run two production lines and support additional lines as necessary. Expected to be operational by 2012, it will produce WhiteWave-Alpro foods.

Kwik Trip Inc. is expanding its dairy capabilities in LaCrosse, WI by adding a new 80,000-sq.-ft. ice cream facility, which will allow the company to triple its production. Construction is expected to begin this fall, and the facility should be operational by spring of 2012. Adrienne’s Gourmet Foods (Santa Barbara, CA) is shutting down its California operation and moving to a new 120,000-sq.-ft. manufacturing facility in Sandusky, OH. The company specializes in making cookies and crackers as private-label products. The facility has a larger footprint, and the design makes it easier to keep certain operations separate.

Snack food processor honored as FE’s Plant of the Year

M

elissa Shearer, Shearer’s Foods vice president of communications, accepted the Plant of the Year Award from FE Editor in Chief Joyce Fassl at FE’s Food Automation and Manufacturing Conference 2011, held last month in Palm Beach FL. Shearer’s new Massillon, OH facility was planned with sustainability in its core design and was recently awarded LEED platinum certification by the US Green Building Council. Phase 1 of the “Millennium Facility” was completed in March 2010. “ With the building of the Millennium manufacturing facility, Shearer’s sustainability initiatives have received an overwhelming amount of attention,” said Shearer in her acceptance speech. “Further sustainable initiatives are being explored, which we plan to share with our associates, our community, our industry and other industries as well.” Sustainability is not a new concept at Shearer’s. In 2006, the snack food processor saw the benefits of participating in the US Energy Star program and began changing out large, clunky, energywasting motors with smaller, variable frequency drives and energy-efficient motors. Today, the new facility is all about making as much product as possible with the least amount of natural gas, electricity and water. Making cornmeal for the tortilla line is one example where innovative design makes a big difference. The corn cooking and transfer system saves 1.7 billion BTUs per year in gas consumption (16 percent of total use) while reducing water consumption by a third, compared to available industry-standard equipment. Retro-fitted ovens provide just the nec-

` FE Editor in Chief Joyce Fassl presented the 2011 Food Plant of the Year Award to Melissa Shearer, vice president of communications of Shearer’s Foods, and Scott Weyandt, director, sustainability & compliance of Shearer’s Foods, during the Food Automation & Manufacturing Conference held last month in Palm Beach, FL.

essary heat, and exchangers are used to reclaim heat. Industrial networking systems, PLCs, PCs and software automate the process and allow for quick changeovers, while a customized statistical process control system monitors quality, food safety and compliance. With electronic documentation, Shearer’s found it relatively easy to attain third-party SQF Level 3 certification, and in much shorter time than processors without electronic documentation. The typical time of a year or so was reduced to two and half months. Phase 2 of the project will double the floor space to more than 110,000 sq. ft. with additional lines and brick and mortar. An anaerobic digester is in the plans. For more details on the project, see Food Engineering’s April 2011 issue.

www.foodengineeringmag.com | Food Engineering | May 2011

13

MANUFACTURING

`NEWS INDUSTRY & PEOPLE Kraft Foods nominated Dr. Peter B. Henry to its board of directors. Henry specializes in emerging economies and is the dean of New York University Stern School of Business. In another announcement, Kraft Foods reported that Timothy R. McLevish, executive vice president and chief financial officer, will leave the company. He will shift his CFO responsibilities to David Brearton, currently executive vice president, operations.

Uni-World Capital, L.P., a private equity firm, acquired the brands and assets related to the beer business of the Iron City Brewing Company. The brewery’s headquarters will remain in Pittsburgh, and beer production will continue in Latrobe, PA.

the Pringles business into Diamond Foods in a transaction valued at $2.35 billion.

The Fieldbus Foundation appointed Larry O’Brien, formerly of ARC Advisory Group, as its global marketing manager.

Golden Peanut Company, a wholly owned subsidiary of Archer Daniels Midland Company, appointed Joe Campbell as its vice president, procurement and Bob Parker as its president, industry relations and seed.

Cargill Kitchen Solutions will invest $1.3 million to upgrade its wastewater treatment capabilities at its Mason City, IA location. The European Commission (EC) approved the tender offer by DuPont Denmark Holding ApS to acquire all of the outstanding shares of Danisco.

Diamond Foods, Inc. and The Procter & Gamble Company announced the

General Colin L. Powell, USA (Ret.)

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PACK EXPO Las Vegas Show.

will be the keynote speaker at the 2011

The Grocery Manufacturers Association announced that retired Chairman of the Board, President and CEO of Del Monte Foods Richard G. Wolford and Campbell Soup Company President and CEO Douglas R. Conant were selected to receive the 2011 GMA Hall of Achievement Awards.

Industrial Magnetics, Inc., a manufacturer of magnetic components and assemblies, promoted Dennis O’Leary to the position of general manager. Yaskawa America, Inc. appointed Masahiro Ogawa as its new CEO. He follows retiring Gen Kudo. Ogawa has 24 years of experience with the company.

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F O O D PA C K A G I N G Kevin T. Higgins, Senior Editor

Always be continuous

`

Flexibility and lean manufacturing are driving the growth of robotics, but mechanical motion still rules high-volume packaging.

R

obotic motion is pervasive in contemporary machinery for secondary packaging , but the ABCs of highspeed production suggest continuous motion machines will be part of the landscape for decades to come. “Unless controlled stopping and star ting is a requirement, continuous motion is still the standard,” believes Jim Stanger, a machine designer with Portland, CT-based StandardKnapp Inc. “It’s more robust than robotics, and continuous flow operates at greater speeds.

` High speed and reliability have made the 296T tray packer the standard for AriZona Beverage Co. and its copackers. Source: StandardKnapp Inc.

That’s what has been driving the market since the beginning of time.” Stanger’s career doesn’t stretch quite that far back, but he has designed Standard-Knapp equipment for 40 years, including the Continuum 296T tray packer. AriZona Beverage Co.’s Vincent M. Lotito is among the satisfied clients. The vice president and his director of operations, Mike Putnam, selected the machine for its tool-less changeover feature, reliability and flexibility five years ago when upgrading a line at their Maplewood, NJ plant. The machine boosted speeds about 20 percent to 68 12-packs a minute for 16- and 20-oz. cans and bottles. The fast-growing beverage bottler since has encouraged its copackers to follow its lead. “With the older equipment, it was typical to have a half-hour or one-hour period where you were tweaking things to maximize efficiency,” says Lotito. The newer units changeover in half the time, and operators, not mechanics, execute the procedures, allowing a rapid return to optimum operating speed. Continuous improvement has kept the 296T relevant, with additional servo motors helping push top speeds to about 80 cases a minute. Still, the machine must prove its stripes with every new installation. Qualification tests become more demanding every year: “Years ago, reliability on this type of equipment was 80 percent, and the customers were happy with that,” recalls Stanger. Today, 98 percent is a minimum threshold. “Robotics is necessary and serves a purpose,” he reflects, “but for mass flow of up to 2,400 cans a minute that have to be collated on the fly, continuous motion is still the way to handle it.” ❖ For more information: Jim Stanger, Standard-Knapp Inc., 860-342-1100

www.foodengineeringmag.com | Food Engineering | May 2011

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F O O D PA C K A G I N G

Automated tube tester debuts

B

urst tests, leak detection and other package-integrity testing remain largely lab-based, manual processes, even as the machines that produce those packages accelerate their output capabilities. At the request of a toothpaste manufacturer, a British firm that fabricates high-speed packing machines for tube-filled products has developed an at-line standardized testing system that takes some of the subjectivity out of those tests and hopefully allows package formers to improve production consistency and reduce waste. Called the Q-Test, the automated tester was designed to test laminated and extruded-plastic tubes, container options largely relegated to pharmaceuticals and cosmetics in North America but formats popular for food products in Europe and Japan. Development work began in late 2008, when Colgate-Palmolive Co. asked Cerulean, a London area division of Molins Plc, to devise a machine to test tubes that feed into the packing/filling machines it manufactures. The first inspection machine installation will be at Colgate’s Morristown, TN toothpaste plant. Q-Test has two modules, explains Peter Wilson, Cerulean’s global sales manager: pneumatic measurements that test for leakers

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May 2011 | Food Engineering | www.foodengineeringmag.com

` Laser and high-resolution optics provide consistent, quantifiable measurements of the key parameters of tubes used to package foods and other products. Source: Cerulean.

by pumping pressurized air into a tube at 5psi and, for burst tests, 30psi. The machine also performs torque measurements of the tube’s cap. A second module utilizes laser and a camera with a highresolution lens to inspect side-seam integrity, as well as measure length, diameter and ovality. Currently, QA technicians use highpower microscopes to examine the 1.5mm-wide seams, but that is “labor intensive and open to interpretation, with potential inconsistent results,” he says. Automated inspection takes about a minute. Although the machine is designed for tube inspection, Wilson believes it can be adapted for plastic bottles and other containers. “We already have a list 3-ft. long of things the machine doesn’t currently do, so the Q-Test 3 is on the horizon,” he says. ❖ For more information: Peter Wilson, Cerulean, 44 1908 396034, [email protected]

Cut Your Cost 9 Ways with One Ultra-Economical Conveyor installation cost 1 Cut Easy conveyor routing

at any angle (over, under or around obstructions, through small holes in walls or ceilings) conforms to process layouts, drastically cutting installation costs, while consuming minimal floor space.

initial cost 2 Slash Flexicon conveyors

on maintenance 3 Save Rugged inner screw is

less energy 4 Use Low horsepower motors,

at multiple 5 Convey locations

on sanitary 6 Save construction

costly 7 End contamination

cleaning costs 8 Reduce Removable end cap

disparate 9 Convey materials

cost far less than drag chain conveyors, bucket elevators, pneumatic conveying systems and other conveyors of equivalent capacity, both initially and in operation.

Available mounted on mobile bases with casters, Flexicon conveyors with hoppers, dust collectors and other accessories can operate at multiple locations, eliminating the need for dedicated conveyors.

See why thousands of engineers like you have purchased more Flexicon conveyors than all competitive designs combined.

allows reversing of screw for evacuation of material, in-place flushing of crevicefree interior, or quick removal of screw for sanitizing—all with minimal labor or downtime.

the only moving part contacting material (no internal bearings) yielding ultra-high reliability with little maintenance cost or downtime.

Other conveyors can command high premiums for food, 3-A dairy and pharmaceutical models, but Flexicon conveyors can meet sanitary requirements at comparatively low cost.

simple gear reducers and ultra-efficient operation significantly cut energy cost per volume of material conveyed.

Enclosed tube prevents dust and spillage, eliminating cost and quality concerns associated with contamination of your product and plant environment.

Handle sub-micron powders to large pellets including non-free-flowing products that pack, cake, seize, fluidize, abrade or smear, with no separation of blends, often eliminating the need for multiple units.

visit flexicon.com

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© 2010 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

Y-0802

USA [email protected] 1 888 FLEXICON

F O O D PA C K A G I N G

Effervescent juice in a can

H

ealthier eating trends are sometimes cited for declining sales of carbonated soft drinks, but at least one juice maker believes the key to increased sales requires effervescence. Lakeville-Middleboro, MAbased Ocean Spray Cranberries Inc. is rolling out four new sparkling juice drinks, the first carbonated blends in its history, according to a company spokesman. The products, which launched in February with a sample giveaway and couponing to Facebook fans, are 70 percent juice and 30 percent carbonated water. The four varieties—regular and diet versions of cranberry and pomegranate blueberry—are packaged in 8.4-oz. cans, a choice dictated by the desire to offer the blends in a singleserve container, the company says. Most of Ocean Spray’s

` Ocean Spray debuted its first carbonated juice drinks in February with a sample giveaway to its Facebook fans. Source: Ocean Spray Cranberries Inc.

juices are filled in 64-oz. PET containers. The cans are sold in four-packs, with a $3.79 suggested retail price. “We hope to provide the right mix of the bubbly refreshment consumers crave with the tasty goodness of Ocean Spray juices,” states Marketing Vice President Larry Martin. ❖

Solutions for you and you alone. No

ceptions.

IIf there h iis one thing hi 0 years off iindustry d i h h us, iit’s ’ that h products d hi h over 50 experience have taught which may have worked in the past may not be sufficient to provide adequate lubrication in the h ffuture. At JAX lentless in our quest st to provide vid you with i h the he mostt inno ive and indi id li d 800.782.8850 JAX, we are relentless innovative individualized llubricant lub i l i d the h lif hi d d i d iincrease production. d i www.jax.com solutions to extend life off your machinery, reduce downtime and Just a our needs are ever-ch i , so is our line of iindustrial d strial llubricants b icants – because af ll as your ever-changing, after all, the th h thing hi ki l i there iis no such as a cookie-cutter solution. See Food Master, p. 76-77

FEX09074JAX.indd 1

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May 2011 | Food Engineering | www.foodengineeringmag.com

8/8/07 10:46:17 AM

FOOD SAFETY

Food safety plans for the small business owner

`

There are simple and inexpensive ways to build a program that protects your customers and your business.

O

ne part of the Food Safety Modernization Act (FSMA) that has not gotten much attention is the waiver exempting small businesses. While this is a noble sentiment, a small processor has just as much, if not more, of a chance of causing problems as a large company. Even if a small processor is not required to establish a food safety management system, the owner would be wise to ensure the safety of the establishment and the foods it produces. Developing food

Richard F. Stier, Contributing Editor

be to verify certificates of analysis (COAs) for sensitive ingredients. Also, if the operator is buying produce, it should mandate all growers exercise good agricultural practices (GAPs) and get this commitment in writing. In addition, small processors should ask all packaging suppliers to provide letters of guaranty that their products are approved for use as food contact packaging and certificates of analysis. To assure requirements are met (see chart below), owners should take a HACCP class or find

What should small operators do? According to the provisions of the FSMA, operators must:

✔ Establish a HACCP plan that includes prerequisite programs. ✔ Maintain records documenting control systems. ✔ Conduct a food defense audit to evaluate the potential for intentionally introduced hazards. ✔ Have the ability to trace ingredients and finished products.

safety programs is a great deal of work and might seem to be an endless and expensive exercise. However, there are simple, inexpensive ways to build a program that protects your customers, your business and your livelihood. Processors should ensure the ingredients and raw materials used are of high quality. Unfortunately, small processors, such as bakers or cheese makers, do not have the expertise or resources to build a vendor quality program including audits and extensive testing. These processors can, however, ask vendors to supply specifications for all ingredients, as well as certificates of analysis and audits that have been done at the vendor’s facility. The small operator’s cost of this program would

a good self-tutorial. Classes provide an opportunity to ask questions and interact with others in the industry. University extension staffs are a great source and can serve as an ongoing reference. Once a small processor understands the basic principles of HACCP, he or she can begin to implement the program. The complexity and type of programs vary for each operation, but all should include pest management, water quality, personal hygiene for workers, chemical handling and control, glass and brittle plastic, cleaning and sanitation, and preventive maintenance. Only when the prerequisite programs are completed should the company start working on its HACCP plan. ❖

www.foodengineeringmag.com | Food Engineering | May 2011

23

FOOD SAFETY

` U P DAT E

HARD SURFACE DISINFECTANT Ecolab’s Virasept ready-to-use hard surface disinfectant is proved to be effective against Clostridium difficile spores. The disinfectant works within 10 minutes of application against Clostridium and in four minutes or less for a broad spectrum of other pathogens including MRSA, VRE, E. coli, Norovirus and others. The formulation is recommended for daily cleaning of hightouch room surfaces. Ecolab; 800-352-5326; www.ecolab.com

KOSHER-CERTIFIED CLEANER Sunburst Chemicals’ rapidly biodegradable Solid Green 14 all-purpose cleaner, Solid Green 40 pot and pan detergent, Bio Clean multi-purpose germicidal/detergent/disinfectant/sanitizer, Score non-caustic degreaser and Sentry no-rinse quat sanitizer are now certified Kosher year-round, excluding Passover. Each solid capsule yields from 144 up to 1,800 gallons of use-solution, depending on the particular product and concentration used. Solid Green 14 all-purpose is a mild, non-caustic degreaser that safely emulsifies heavy loads of unburned grease and oil from all surfaces, including stainless steel. Sunburst Chemicals; 800-899-7627; www.sunburstchemicals.com

BIOFILM DRAIN CLEANER Zep Biofilm Drain Purge cleans organic debris from drains and piping, killing harmful bacteria that cause odors and illness. The cleaner attacks the biofilm, penetrating and removing it while acting as a bactericide, slimicide and algaecide. Zep; 877-428-9937; www.zep.com

* TankJet® 360 Tank Cleaner

Downtime for tank cleaning can significantly impact production levels. Our recently expanded tank cleaning product line includes many solutions to clean your tanks in less time – and return them to service more quickly without compromising cleaning quality. Whether your tanks are 2 ft. or 100 ft. (0.6 or 30 m) in dia.; require rinsing or high-impact cleaning, our local sales engineers will help you select the right tank cleaner. The results: UʘVÀi>Ãi`Ê«Àœ`ÕV̈œ˜Ê̈“i UÊ“«ÀœÛi`ÊVi>˜ˆ˜}ÊVœ˜ÃˆÃÌi˜VÞÊ

i>À˜Ê“œÀiÊ>ÌÊÌ>˜ŽiÌ°Vœ“

TankJet 65 Tank Cleaner

TankJet AA190D Tank Cleaner

TankJet 18250A Tank Cleaning Nozzle

* Reductions in cleaning time will vary based on current cleaning methods and the tank cleaner installed. Multi-hour operations can often be reduced to 60 minutes or less.

24

May 2011 | Food Engineering | www.foodengineeringmag.com

FOOD SAFETY

` U P DAT E

FOAM-BASED CLEANING

HAND SANITIZER CLEANERS Kutol’s line of hand cleaners combats the bacteria, viruses and fungi that food industry workers face every day. Available in a variety of dispensing systems, the company’s NSF-rated E2, HSC bacteria-controlling hand sanitizer/cleaner is suited especially to meat and poultry industries, and has a USDA rating that helps meet HACCP requirements. A foaming E2 sanitizer cleaner is available for the company’s wall-mounted EZ-Foam dispensers. Both products contain myristalkonium chloride and quaternium-14. Also available are instant hand sanitizers that require no rinsing, and are NSF E3 rated. Kutol Products Company; 800-543-4641; www.kutol.com

Diversey’s Enduro Power is a foam-based cleaning solution designed specifically for food manufacturing, dairy and brewery operations. The cleaning product improves penetration of dirt and soil, reducing the need for reapplication. The cleaner’s formula also makes it easier to rinse, reducing total cleaning time, water and energy consumption. The product is safe for use on a wide range of surfaces. Diversey; 262-631-4001; www.diversey.com/enduropower.

Hang up your gloves. A better way to wash and sanitize buckets is right at your fingertips! Presenting the Douglas Model SD-36-BW This easy to install, high volume workhorse provides superior cleaning in a fraction of the time. This unit features a split-door design, recirculating wash water, flexible racking system, selfcontained water heating, heavy duty 15 H.P. pump, preprogrammed cycle times and a digital display to monitor key performance criteria and service requirements. So meet today’s high standard for cleanliness and sanitation while minimizing labor, water and energy costs.

CALL 800-331-6870

for pricing, literature and specifications.

See Food Master, p. 54

2101 CALUMET ST. • CLEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX (727) 449-0029 • www.dougmac.com 26

May 2011 | Food Engineering | www.foodengineeringmag.com

Innovative extrusion processes without limits. With our extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success for any product concept. With the addition of Aeroglide® to the Buhler family, we now offer one of the most complete lines of process technology available anywhere. From raw material handling, cooking and shaping through extrusion to drying of finished products - from breakfast cereals and snack foods to modified flours and starches and texturized proteins. In short: extrusion processes without limits. Visit Buhler at Interpack. May 12-18, 2011. Dusseldorf, Germany. Buhler Booth: Hall 3, # 3C43/D28. Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, 763-847-9900 [email protected], www.buhlergroup.com

Innovations for a better world.

PERFORMANCE THROUGH ENGINEERING BETE HydroWhirl™ Orbitor

MaxiPass™ (MP) Nozzles from BETE

The XA Nozzle System from BETE

A New “Revolution” In Tank Cleaning BETE’s new HydroWhirl™ Orbitor is a versatile Clean-In-Place (CIP) rotating tank cleaning machine that combines high-impact cleaning efficiency with extended operating life, reduced life cycle costs and simple on-site service. The Orbitor can be completely stripped and rebuilt for maintenance ON-SITE in less than 15 minutes.

The ultimate in clog-resistance with the largest free passage available in a full cone nozzle Two unique s-shaped internal vanes allow free passage of particles equal to the orifice size, making the MP perfect for handling dirty, lumpy liquids. Pattern uniformity is exceptional, providing an even distribution throughout. Reliable spray under difficult conditions. Low flow model available.

Produces a no-drip or high-speed spray shut-off BETE’s low flow, air atomizing XA series nozzles provide very low flow rates. They are available in eight different spray patterns and numerous flow rates. The XA nozzles can be supplied with a number of hardware options to allow cleanout, shutoff of both. Hardware options are available in manual and pneumatic versions.

BETE is your strategic partner for engineered spraying solutions. Tank cleaning Mixing Coating Washing Drying Packaging

BETE HydroWhirl™ S A slotted rotating spray nozzle for quick, efficient tank cleaning The HydroWhirlTM S tank washing nozzle, with a 360° coverage, directs the cleaning water through a rotating head at the tip of the spray assembly. This spray pattern uses impact and repetition to quickly wash the tank which breaks up and removes contaminants. The low-maintenance, dual-bearing design, uses less water and lower pressure than static tank washers.

Twist & Dry™ Nozzles from BETE The Twist & Dry™ spray dry nozzle features the innovative thick swirl unit The robust design lasts longer, reducing dryer operating costs. The patented locking mechanism allows for quick and easy change-out and maintenance. BETE has expanded the range of the Twist & Dry™ series with the new TD-K, capable of operating at up to 10,000 psi.

BETE’s HydroWhirl tank cleaning nozzle

IN-HOUSE CAPABILITIES • 3D design, modeling, and measurement tools to create customized nozzle solutions • State-of-the-art spray laboratory to verify performance and supply detailed test results • Investment casting foundry for complete quality control and fast delivery • Specialized fabrication and welding expertise for multi-component assemblies PERFORMANCE THROUGH ENGINEERING Let our experience provide you with a recipe for success. www.bete.com

BETE Fog Nozzle,Inc.

BETE Fog Nozzle,Inc. BETE Fog Nozzle, Inc. 50 Greenfield St. Greenfield, MA 01301 T (413) 772-0846 F (413) 772-6729 www.bete.com

TECHNOLOGY S O U R C E B O O K Focus on Valves and Weighing Equipment

POST-BAKING DRYERS Eliminating the final drying requirement from the last third of an oven line, Radio Frequency Macrowave post-baking dryers utilize radio frequency energy that preferentially heats and dries the moist areas of cookies, crackers and snack foods, enabling conventional ovens to run at the maximum speed for product production with the correct loft, crumb structure and color. The technology is “instant-on/instant-off,” using energy only during the treatment process. Developed for high-volume production, the dryers are available in band widths up to 64-in. wide. Radio Frequency Co., Inc.; 508-376-9555; www.radiofrequency.com

HYGIENIC ROTARY VALVES USDA approved following certification in compliance with the USDA Dairy Grading Branch, Coperian hygienic ZRD discharge valves and ZXD blow-through valves are designed for applications involving frequent changeovers from one product to another, for the processing of products with adhesive tendencies, in pneumatic conveying systems and for the discharge of powdered and granular materials. The smooth-surfaced rotary valves have no dead spots and are manufactured completely in stainless steel. They are fitted with FDA-compliant sealing materials as standard. Slots and gaps have been reduced; unavoidable slots and/or gaps are flush-sealed, both on the inside and outside of the valves. Coperion GmbH; www.coperion.com

CUSTOMIZED AIRLOCKS AIRLANCO airlocks are available in customized fabricated and machined models

for pneumatic systems, gravity feeds and volumetric discharge devices. Fabricated models handle grain, food, feed and dust collection where pressure differentials are 20 in. of water column or less; urethane wipers provide a tight fit between fabricated rotors and housings. Machined airlocks have cast housings and are designed for higher pressures as well as difficult and abrasive materials; rotor-to-housing fit is 4- to 6-thousandths of an inch. AIRLANCO; 800-500-9777; www.airlanco.com

TANK CLEANER Used for removing stubborn residues from tanks up to 100 ft. in diameter, the Spraying Systems TankJet 360 fluiddriven tank cleaner provides consistent impact over the entire pressure range. Equipped with a dual- or triple-nozzle hub and high-impact solid stream nozzles that rotate 360° in horizontal and vertical planes, the unit creates a crisscrossing pattern to clean and remove sticky residues. The compact, lightweight cleaner can be installed permanently or moved from tank to tank; it fits in tank openings as small as 6.25 in. and operates at flows up to 300gpm (1135.6 l/min.). The cleaner is available with 3 gearbox designs: food-grade, oillubricated or flow-through. Spraying Systems Co.; 630-6655000; www.spray.com

COMBINATION SCALES CombiScale PrimoWeigher 360 openframe combination scales have 10-, 14-, 16-, 20- and 24-head configurations with 1.5-, 2.5- and 5-liter bucket sizes. Operating at speeds up to 80 to 200+ cycles/min., the scales run a range of products such as bakery, bulk, cheese, coffee, confectionery, dry goods, fresh meat and produce, pet food, powder and snack food. CombiScale Inc.; 305-895-8909; www.combiscale.com

www.foodengineeringmag.com | Food Engineering | May 2011

29

TECHNOLOGY S O U R C E B O O K

SMART PHONE APPLICATION The Lightning Pick LP mobile web application provides Lightning Pick users with real-time productivity views, operations management controls and system diagnostics through a mobile or smart phone. The mobile app offers real-time dashboard-style updates on Lightning Pick-controlled operations including pick rates, area overview, order progress and other facility statistics Lightning Pick Technologies; 800-827-8878; www.lightningpick.com

ETHERNET IP COUPLER The Advantech APAX-5072 high-density Ethernet IP communication coupler features Open DeviceNet Vendors Association authorization, allowing it to link with any Ethernet IP master. It features 2 RJ-45 ports with the same IP address for building daisy chains to connect remote I/O devices directly without an additional Ethernet switch, and provides dynamic configuration that allows users to configure different channels with different types and ranges in one module. The coupler can also connect APAX digital I/O modules or analog I/O modules to build remote I/O systems for fulfilling PLC or control application needs. Advantech Industrial Automation Group; 800-205-7940; www.advantech.com

SANITARY VERTICAL ELEVATOR

See Food Master, p. 53

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May 2011 | Food Engineering | www.foodengineeringmag.com

Capable of elevating cases to a height of 15 ft. in areas with a minimum amount of floor space in which to gain the elevation, the Keenline Liftavator sanitary vertical elevator can handle different case sizes delivered in a random fashion. It accepts each case, indexes it vertically one position, accepts the next case and indexes it one position. The elevator continues this process as it moves the product to the top, where a pusher pushes each case, in its turn, onto the transport conveyor. Keenline Conveyor Systems; www.keenline.com

TECHNOLOGY S O U R C E B O O K

COMPACT BAGGER Used with meat, seafood, cheese, grain, nuts, fruits and vegetables, the WeighPack Bingo Bagger XL can handle bags 16- to 20-in. wide and14 to 24-in. long. Operating at speeds up to 25 cpm, the bagger offers vacuum and gas flush options at the sealing station. Compact in size, it has 304 stainless steel standard food-grade contact parts and features a stationary product funnel, adjustable bag wicket holders and pins. WeighPack Systems Inc.; 888-934-4472; www.weighpack.com

DIGITAL MULTIMETERS OMEGA HHM10, HHM20 and HHM30 Series of handheld digital multimeters have a GS-Mark EN61010-1 approval, Over-Voltage Category II 600 Vdc/ Vac; pollution degree. The HHM26 and HHM28 models have RS-232 interface. All the multimeters include a free protective rubber boot with tilt stand, set of safety test leads and 9V alkaline battery. They have a stated accuracy at 23 +/-5°C < 75% RH and a battery life of 200 hours. Their dimensions are 7.6 in. x 3.6 in. x 2.1 in. OMEGA; www.omega.com

STRETCH WRAP SYSTEM Available as an enhancement to the Muller Octopus line of stretch wrap equipment or as a retrofit to most existing machines, the Muller OctoMAX stretch wrap system utilizes proprietary hardware and software to monitor and measure equipment and film effectiveness. It allows users to ensure the optimal settings, pre-stretch gears, number of wraps and amount of film, and monitors the performance of the film. Connected through the Internet, the system immediately notifies the user via e-mail if something goes wrong with either the machine or film; real-time information is also available on the enhanced operator interface or HMI display. ITW Muller; 800-628-6787; www.itwmuller.com

Answers.

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www.foodengineeringmag.com | Food Engineering | May 2011

31

GET RECESSIONFIGHTING SAVINGS WITH CLAYTON STEAM BOILERS

TECHNOLOGY S O U R C E B O O K

GATE VALVES

Worldwide Energy Savings: $134-Million!

Engineered for material handling applications that require daily cleaning or sanitation of equipment, Vortex Quick Clean orifice gate valves can be disassembled, cleaned and reassembled without tools. They feature an allstainless steel, weather-resistant design and include hard polymer seals. USDA Standard approved, the valves can be applied to control, shut off or meter the flow of sticky or reactive materials in gravity-flow applications. Vortex Valves; 785-825-7177; www.vortexvalves.com

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You can save a bundle in energy costs and gain production-boosting performance, too. How? With Clayton steam boilers, noted worldwide for keeping fuel consumption low and reducing greenhouse gas emissions (In just one year, for example, plants around the globe that used Clayton steam boilers saved $134-million in fuel costs.) Other benefits: unique counterflow technology for better efficiency, small footprint, low NOx emissions, quick start-ups, even pressure when demand fluctuates and great performance on numerous fuels or combinations. Clayton steam boilers. Benefiting budgets for 80 years.

17477 Hurley Street City of Industry, CA 91744-5106 800.423.4585 tel • 626.435.0180 fax email: [email protected] www.claytonindustries.com

WEIGH MODULES Complementing all systems, machines and instruments, METTLER TOLEDO WMS highresolution weigh modules can be integrated into a variety of automated processes. Compact in size, they have a wide weighing range with intelligent mechanical and electrical interfaces; an FDA-compliant stainless steel design includes overload stops. The modules produce up to 92 updates/sec. and up to 4,000,000 points of resolution (210g x .1mg; 400g x 1mg; 400g x .1mg) to track and control dosing processes in real time. They are controlled directly using a PC via RS232 or RS 422, and feature a range of weigh platforms for specific designs to allow weighing on top of or under the modules. METTLER TOLEDO, Inc.; www.mt.com

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See Food Master, p. IFC 12

TECHNOLOGY S O U R C E B O O K

FOOD-SAFE GRAPHITE LUBRICANT Able to withstand the extreme environments of food processing facilities, Chain Guard food-safe graphite 220 lubricant is a high-temperature, ester-based, fully synthetic chain oil fortified with anti-wear additives and oxidant inhibitors. It has a flash point of 527ºF and a recommended operating temperature range of up to 1,200ºF. Chain Guard Industrial Lubricants; 905-475-9292; www.chainguardlubricants.com

BEARING PROTECTION Protecting bearings from electrical damage as well as from lubricant loss and contamination, the Garlock SGi shaft grounding bearing isolator combines the technologies of a non-sparking bronze labyrinth seal and a shaft grounding ring in a single unit. The isolator diverts harmful currents safely to ground, bypassing the bearings entirely and extending motor life. The FiberLock channel permanently secures circumferential rows of conductive microfibers, preventing their dislocation and the resulting accidental contamination of the bearing. The isolator also provides an IP56 non-contact isolation seal that withstands dust and powerful jetting liquids. Withstanding operating temperatures from -22°F to 300°F, the unit is available for motor shaft sizes from 0.875 to 6 in. in flanged, flangeless and custom configurations. Garlock Sealing Technologies; 800448-6688; www.garlock.com

Increase Productivity & Reduce Maintenance! Like a powerful cleanup hitter, Quickdraft Engineered Solutions and Venturi Technology come through for you, blowing both exhaust and conveying problems out of your plant.

Venturi Powered Conveying Solutions: 0‰`mh’A‰hh9‰IAŠ• 0‰h Š„ h dK„ŠA„ 0‰h‰Š„‰h‰dK„ŠA„ 0‰d1A„A h9 h91 1ŠK ŠK’KŠ• 0‰d1A„A‰h91ŠK’KŠ•‰

0‰A91A‰KdŠAdd1A 0‰A91A h9 h91  Š h h„„ „„ 0‰A91A‰h91Š‰h„„

MACHINE VISION SOFTWARE Cognex VisionPro 7.0 machine vision software includes a functionality to simplify the specification, development and maintenance of inspection applications. An image grading utility grades product images and specifies different defect types within each image. A verification tool confirms the vision system is producing the desired results by comparing the grades of the inspection results with stored and graded images. The software also features a best-in-class barcode reading tool optimized for omni-directional and difficultto-read one-dimensional barcodes. Cognex Corporation; www.cognex.com

Break-apart Venturi

Sanitary Cyclone Air Separator

Material Intake Hopper

1-855-VENTURI

330-477-4574 [email protected] quickdraft.com See Food Master, p. 90 www.foodengineeringmag.com | Food Engineering | May 2011

33

TECHNOLOGY S O U R C E B O O K

LARGE-CHARACTER PRINTER ELECTROMAGNETIC SCREENERS Available in a variety of drive designs, Eriez electromagnetic screeners reliably size, scalp or de-dust dry bulk solid materials. The high-frequency, 3,600 vibrations per minute (3000 VPM @ 50 Hz) B and C models are used for de-dusting and other fines mesh (4 to 200 mesh) separation; models are also available for Class II, Div. 1, Group F and G environments. Operating at a fixed 1,800 vibrations/min., HD models are suitable for a range of applications. Eriez; 888-300-3743; www.eriez.com

34

Engineered for companies that print large, variable data codes on porous or nonporous substrates, the Videojet 2120 large-character inkjet printer can apply characters on cardboard, paper, plastic and foil. Multiple print head and ink options allow configuring different products and packages, regardless of the substrate. The 700 series print head and inks print characters up to 50mm high on porous materials. The 800 series print head and inks work on nonporous surfaces and a range of plastics, and print characters up to 92mm high. Videojet; 800-843-3610; www.videojet.com

May 2011 | Food Engineering | www.foodengineeringmag.com FEX04074Mart_2.indd 1

3/8/07 3:09:13 PM

TECHNOLOGY S O U R C E B O O K

ELECTROMAGNETIC FLOW METERS

PISTON PUMPS

Suitable for aseptic processing, the GEA Diessel IZMAG electromagnetic flow meter includes Bluetooth technology for remote data collection and automatic calibration. Used for metering milk and milk products, it provides accurate flow measurement from collection through to final processing for whole milk and raw milk, standardized milk with 0.3% - 3.8% fat, ewe’s and goat’s milk, soy milk, extended shelf life milk, condensed milk and coffee cream, cream, yogurt and kefir, whey, buttermilk and soured milk. It also measures the quality of milk collected by the road tanker; measures and controls additive dosing levels; and controls the filling process at the end of the production chain. GEA Diessel GmbH; www.diessel.com

Parker Hannifin high-performance P1/PD hydraulic pumps are available in 18, 28, 45, 60, 75, 100 and 140cc models for use in a variety of medium-duty mobile (P1) and industrial (PD) applications. Rated for continuous operation at pressures up to 280 bar, the pumps have SAE and ISO standard mounting flanges and ports, with a choice of end or side inlet and outlets. Options include standard pressure limiters, with or without torque control; load sensing with pressure limiter and/ or torque control; and pilot-operated pressure limiters with a choice of an ISO 4401 interface, mechanical adjustment and vent port, and electrical adjustment. Parker Hannifin; www.parker.com

Ready to try the latest in Mixing Technology? ✔ Vacuum suction delivers powder up to 400 lbs/min ✔ Drastically reduce batch times ✔ Wet out and instantly disperse with no fish-eyes or agglomerates ✔ Eliminate bridging at any viscosity range ✔ Floor level powder/liquid addition reduces operator injuries ✔ Induct liquids from drums with optional wand ✔ Field proven on sugars, salt, phosphates, dairy powders, starches, gums, carbomers, soy, carrageenan and more

See Food Master, p. 5-7

See the

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in Action! Visit our website www.admix.com/fastfeed.htm www.foodengineeringmag.com | Food Engineering | May 2011

35

TECHNOLOGY S O U R C E B O O K

For consistant food grade lubricant quality, buy from a company that is NSF H1 and ISO 21469 CERTIFIED. Summit Industrial Products is one of the fast growing synthetic food grade lubricant manufacturing companies in the US.

Try us out and see why! MODULARIZED LABELER Suitable for cold-glue, pressure-sensitive, hot-melt or shrink-and-stretch sleeves, the Krones DecoBloc modularized labeler features a Sleevematic carousel, Shrinkmat tunnel and Linadry unit for pre-drying containers; different machine sizes offer outputs up to 72,000 containers/hr. Docking stations feature motorized height adjustment. Servomotors provide accurate dress positioning. An option is available for camera-based alignment of the containers on an embossed marking or container contour to ensure labels or sleeves are optimally positioned in relation to the bottle. Krones AG; www.krones.com feature stabilizes tall loads. It provides inventory control, production statistics and interface with a plant host via onboard and off-board software. Amerden Inc.; www.amerden.com

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GUIDED VEHICLE A flexible material handling link between production lines and warehousing, the Amerden FLA 1650 AGV automatic guided vehicle provides automatic pick up and drop off of unitized loads. The vehicle has deep lane storage capability and can stack 2 or 3 loads high; a safety

Available in 1- to 40-ton capacities and for ambient temperatures from -25°F to 105°F, Mokon Iceman OA Series outdoor air-cooled chillers are engineered for exterior installation. They feature a scroll compressor, and are completely factorywired; reciprocating and semi-hermetic compressors are available in some models. Features include nonferrous components, advanced microprocessor chiller control technology with digital readout, NEMA 4 or 4X remote or local enclosures, green-friendly refrigerant, a UL 508A-labeled electrical sub-panel and NFPA 79 electrical safety standards. Mokon; 716-876-9951; www.mokon.com

May 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY

Removing the oil gland from the tail of chickens as they move along the processing line, the Cantrell OSC-1300 oil sac cutter controls the birds with an in-feed chain and guides the tail into a pinch point where the oil gland is forced into the opening of a V-shaped blade. As the tail is forced across the V-notch, the oil gland is pinched and cut away from the tail. The main chain has replacement components to allow purchasing parts instead of a complete chain assembly. The cutter processes up to 9,000 birds/hr. on 6-, 8- and 9-in. centers. Cantrell; 800-922-1232; www.cantrell.com design with traction; and a polyurethane insole. The 100% waterproof boot provides metatarsal, steel toe and puncture-resistant protection. Tingley Rubber Corporation; www.tingleyrubber.com

PNEUMATIC TRAY FORMERS

METATARSAL BOOT Flexible and comfortable in tough work environments, the Tingley 16-in. metatarsal boot is made from ozoneresistant rubber. It features an internal support system in the areas of the heel and ankle; a rear gusset closure system with no laces to contaminate; a floating metatarsal guard; outsole

Eagle VASSOYOAIR air pneumatic tray formers run a range of corrugated tray designs such as produce, citrus, bliss, showcase and display. Able to produce a large tray size range at speeds up to 22 trays/min., the compact formers are built with a heavy-duty, welded steel tubular frame and low-maintenance drive. They include sealed ball bearings in the blank transfer section with self-cleaning tracks, and use Venturi vacuum technology to extract trays from the hopper. Supplied with an Omron PLC (Allen Bradley optional), the color touch screen HMI allows adjustment of glue patterns. Eagle Packaging Machinery LLC; 305-622-4070; www.eaglepm.com

www.foodengineeringmag.com | Food Engineering | May 2011

nbe-inc.com/food

OIL SAC CUTTER

Process-Specific, cGMP-Ready, FDA, 3-A, USDA Compliant Bulk Material Handling Systems

S O U R C E B O O K

TECHNOLOGY S O U R C E B O O K

TUBE EXPANDER FITTINGS

SORTERS The Key Technology Auto Valve Check feature for new and installed G6 Tegra sorters automates the routine testing of ejection system valves. The sorters remove foreign material and product defects from the acceptable product stream using a close-coupled, high-speed ejector system made up of a series of air jets spaced 6mm apart. The Auto Valve Check is objective and can be performed any time the sorter is not running product. Key Technology, Inc.; www.key.net

Winco metric-sized, RoHS compliant AN 350 tube expander fittings are designed for 25mm OD x 1.5mm wall thickness square tubing. The fittings are typically used for bracing conveyor walls to mount chain return components. J.W. Winco; 800-877-8351; www.jwwinco.com

TOP LOAD CASE PACKER The Douglas TriVex fully automatic top load case packer erects, loads and seals cases. An opposing vacuum cup design ensures cases are erected properly. The packer operates at a rate of 15 cases/min. depending on case size. Douglas Machine Inc.; 320-763-6587; www.douglas-machine.com

EAGLE Product Inspection Division

Formerly Smiths Detection PID

Smiths Detection Product Inspection Division is now EAGLE Smiths Detection Product Inspection Division for food x-ray inspection has been acquired by METTLER TOLEDO and is adopting the EAGLE brand which has been used for its products since 1998. EAGLE is a globally recognised, powerful, precise and respected food x-ray inspection leader, setting higher standards of accuracy, power and adaptability for in-line contamination detection, packaging quality inspection and fat analysis. It has joined METTLER TOLEDO with a family of world-class product inspection brands like Garvens, HI-Speed, Safeline, and CI-Vision. To date, EAGLE has shipped more than 2,000 x-ray systems worldwide. The core x-ray sensor technology at the heart of each EAGLE system is used in virtually every country in the world, with more than 40,000 installations in Smiths Detection mission critical security applications.

38

May 2011 | Food Engineering | www.foodengineeringmag.com

EAGLE customers will continue to benefit from excellent customer service and support for current and legacy EAGLE x-ray inspection products, by the same talented team as in the past.

The EAGLE won’t just survive. It will thrive! Stay focused. Visit us at www.eaglepi.com or email [email protected]

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Just try getting that from overseas. GRAPHITE DRY LUBE DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934 defranciscimachine.com [email protected] 321-952-6600

Forming a quick-drying film, B’laster graphite dry lube spray protects surfaces from extreme pressures and temperatures (-100°F to 850°F). It can be used as a general maintenance lubricant on gaskets, transfer belts and conveyor belts or as a general lubricant for high temperatures, low load, or high rpm slides, rollers, wheels, gears, chains and hoists. The lubricant bonds to rubber, metal, wood and plastic. B’laster Corporation; 800-858-6605; www.blastercorp.com

Bulk Container Dumpers

LIDDING SEALANT RESIN Providing an effective way to make peelable lids for retortable polypropylene (PP) packages, DuPont Appeel 22D843 lidding sealant resin is pellet-blended with a polypropylene sealant resin and then processed to make a lidding structure or sealant layer in conventional extrusion or coextrusion equipment designed for polyolefin resins. Typically blended with PP at addition rates of 20 to 40% by weight, the proportion of the resin in the blend determines peel strength; lower addition rates result in higher peel force and vice versa. Blends of the resin and PP can withstand sterilization conditions from 121°C for 20 minutes up to 134°C for 6 minutes with adequate counterpressure, depending on the type of PP employed. DuPont Packaging & Industrial Polymers; 302-996-7911; www.dupont.com See Food Master, p. 49

Bulk Bag Fillers

Bulk Bag Unloaders

nbe-inc.com/food

Sanitary Plant Design The New Meaning of Clean

40

May 2011 | Food Engineering | www.foodengineeringmag.com

With industry attention riveted on improved food safety, sanitary design of plants is front and center. ` Kevin T. Higgins, Senior Editor

A

day and a half into the trade show, and the engineer assigned to booth duty clearly was frustrated. To drum up booth traffic, his employer devised a short multiple-choice quiz on sanitary plant design. Answer five out of six correctly, and visitors were eligible for a free i-Pad drawing. Most of the questions were softballs, the engineer confided, yet only three of the many visitors managed to clear the knowledge bar. Many of the quiz-takers were owners of small businesses ASSET andMANAGEMENT therefore not intimately involved in the details of hygienic food production, he rationalized. Nonetheless, at a time when ensuring food safety is almost an obsession for many manufacturers and their customers, the gap in understanding sanitary production gives pause. Sanitary design of both equipment and facilities has received considerable attention in recent years, though the basics of good hygienic design have been documented since the time of Louis Pasteur. In a presentation 60 years ago to industry engineers and sanitarians, Paul Laughlin of the Dried Fruit Association of California allowed that the specifics of maintaining hygienic conditions are complex and specific to the food being processed, but the concerns “are fundamentally the same”: control of microorganisms, pest control, waste removal and a committed effort. “We must deal with individuals who have varying concepts of sanitation,” Laughlin said. “Some have a very high sensibility to hygienic decency, while others may not see the necessity.” His association regularly inspected plants and assigned grades in the areas of machinery and equipment and physical plant conditions, and Laughlin allowed that all processors wanted to avoid the negative publicity and financial loss of a recall, but effectiveness hinged on whether they “merely wish to meet the minimum food law requirements as currently enforced or … have a sincere desire to produce a clean product and provide immaculate plant conditions.” Al Koch hasn’t preached the gospel of sanitary design quite that long, though the director of engineering-global biscuit for Kraft Foods’ Nabisco division has proselytized for decades the importance of good design. “So often, engineers design an excellent piece of equipment that functions well but is difficult to clean,” bemoaned Koch in a presentation at Food Engineering’s 2011 Food Automation & Manufacturing Conference held last month in Palm Beach, FL. When deficiencies exist in the building itself, manag-

ers are stuck with the hand they’re dealt, so Koch focuses on raising awareness of the elements of good equipment design when visiting Kraft plants worldwide. He was part of a group of engineers and microbiologists who formed a working group to improve equipment design after the Peanut Corporation of America-related recalls in 2009. Their efforts culminated in the GMA Principles of Equipment Design for Low Moisture Foods. Show and tell works better than verbal discourse when counseling young engineers, particularly when language barriers may exist, and Koch has assembled an expansive photo morgue of good and bad sanitary designs. What is possible must be balanced by what is affordable—if bakeries insisted equipment met dairies’ 3A sanitary standards, “we’d be out of business because our costs would not be competitive”—and indoctrination and reeducation is a never-ending process, he says. Even after 30-plus years, Koch himself is learning new techniques. As a result of his conversations with working group peers from Danone, Kraft bakeries are installing gable tops on the tops of production-floor panels to enhance cleanability and eliminate horizontal surfaces where dirt can accumulate. While industry organizations like GMA and the American Meat Institute are encouraging machine builders to consider sanitation in their equipment designs, “good design often is thwarted by poor installation,” Koch allows. New plant engineers must be taught, and older engineers must be committed to the goal of immaculate conditions. Know the standards Awareness of sanitary design and its role in remaining in the good graces of customers, regulators and third-party auditors is increasing. Even before passage of the Food Safety Modernization Act in December, manufacturers were being challenged to reconsider procedures and protocols through certification programs under the Global Food Safety Initiative (GFSI), points out Darryl Wernimont, a food & beverage market specialist with POWER Engineers Inc. “The GFSI Guidance Document contains commonly accepted criteria for food safety standards, against which any supplier can be benchmarked,” Wernimont writes. Between 3A, baking’s BISSC standards and the AMI sanitary design principles, he believes manufacturers should have a clear understanding of the most appropriate materials of construction, fit and finishes and equipment cleanability to satisfy customers and inspectors alike. www.foodengineeringmag.com | Food Engineering | May 2011

41

SANITARY PLANT DESIGN

` Walkable ceilings that isolate equipment not needed on the production floor are becoming more common as facility designers prioritize sanitary considerations.

Others see an industry in transition. A decade after the concept of silver-ion treatment of food contact surfaces was introduced and seemingly rejected, the technology may be starting to catch on. “There’s a growing acceptance and realization that bactericides can be one of the arrows in the quiver for controlling contaminants,” maintains John Durig, global market development director at Sherwin-Williams Protective and Marine Coatings (see related story on page 46). A major brewery demonstrated the efficacy of silver ion in controlling bacterial growth on floors, when added to the top coats of resin floors. The company deployed the technology in November at one of its breweries and plans to use it in 130 additional plants worldwide, according to Durig.

Others are reserving judgment on seamless floors, except in low-traffic locations. “Urethane won out over the epoxies,” says David Dixon, senior directorstrategic accounts at Burns & McDonnell, a Kansas City, MO-based engineering design firm. “There are only a few places in a food plant where urethane floors will work. You can’t gouge them, so if there’s a nail on a pallet or wheeled cart traffic,” sanitary design may be breached. Floors tend to be the dirtiest area of a plant and the most vulnerable to microbiological risk, which is why Dixon advises, “if you have only one dollar to spend, spend it on the floor.” If additional capital is available, he suggests considering a walkable ceiling with insulated metal panels. Worker welfare should be the next focus, with handwashing stations and showers and company-issued clothing. Air quality is Dixon’s fourth priority, with pressurization and 95 percent filtration trumping other measures. “Wash the ductwork more than once a year,” he adds. Beyond better housekeeping, few options exist to improve air quality, cautions Jim Adler, managerrefrigeration engineering at Hixson Inc., Cincinnati. For example, distributed air should sweep a room, creating “some movement in every area,” he says, but “facility creep” of cobbled-on areas often occurs over time, resulting in dead-air zones. Something in the air Air quality is a thorny challenge in refrigerated environments, particularly when heavy washdown ensures floors are covered by a thin film of water and continuous evaporation occurs. A delicate balance is required to minimize condensation and prevent

Sanitary solutions, then and now Food and beverage facilities usually reflect the best practices in sanitary design when they are built, but times change, and the assumptions made in the 20th century are not necessarily valid in the 21st. More importantly, production managers who are contemplating a major renovation or new facility should look beyond current solutions and consider designs that will remain viable in the years to come, advised William Sander, a project engineer with Hixson Inc., in a Food Engineering Current Acid-proof brick floors Pre-cast or glazed-tile walls Durable, long-lasting fixed walls Concrete mezzanine or lower floor Galvanized sheet-metal ductwork

42

May 2011 | Food Engineering | www.foodengineeringmag.com

webinar on food safety and sanitary facility design. Industrial facilities are built for the long haul, but Sander believes that assumption deserves to be challenged. Product lifecycles are getting shorter, not longer, and the expectation of a 20-40 year useful facility may not be valid. If the expected life instead is 5-10 years, different materials of construction and infrastructure elements may be advisable. Sander offered a few examples of current vs. modified solutions:

Modified Ceramic tile, epoxy or concrete floors Insulated metal panels (IMP) Walls that are adaptable and flexible Walkable IMP ceilings Ducts fabricated from IMP, stainless steel or fabric

A Total Project Solution

™

We see it clearly. Food & Consumer Products Caroline Cooper, 816-822-3831 www.burnsmcd.com/fcp

Whether it’s saving water or managing energy use, sustainability is important. But there’s no point in going green if your plant doesn’t demonstrate the principles of good design and value engineering. In other words, you need the Total Project Solution that Burns & McDonnell provides.

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SANITARY PLANT DESIGN ` Stand-offs on a wire-cut machine for extruding cookie dough and adequate clearance around the the adjoining oven line allow for easy cleaning and are positive examples of sanitary design, according to Kraft’s Al Koch. Source: Kraft Foods Inc.

drying out the food. “Any water loss from the food is a yield problem,” Adler points out. “Keep it cool, keep it dry” is the rule of thumb, but infiltration of outside air adds a wild card to relative humidity. Each facility must be evaluated independently to ensure refrigeration is designed and sized appropriately. “You’re going to pay for every cfm, whether you use it or not,” he says. Air quality is almost an obsession at F&S Produce Inc., a Rosenhayn, NJ operator that processes fresh-cut fruits and vegetables and other refrigerated products. The company currently is adding HEPA filtration in packaging areas. Lou Cooperhouse, an industry expert on chilled foods, recently joined F&S as pres-

ident and chief operating officer. HEPA filtration is one of four defenses against airborne contaminants, he says, a category that extends beyond microbiological threats to include ethylene gas, allergens, gluten and VOCs from onions and other odorous produce. The company recently received USDA certification to process foods containing meat and poultry. It also achieved Level 3 certification under SQF 2000, one of the GFSI programs. Proper design of an air handling system is an engineering challenge that absolutely must be met, Cooperhouse says. “Clean room processing is very well recognized by European chilled foods companies,” with proper pressure, air flow, filtration and humidity control elements that must be synchronized. “You can kick a drain cover and send Listeria flying,” he cautions, and it’s a mistake to give air quality short shrift. “The game of shelf life and safety is a game of singles; there are no home runs.” Batting cleanup at F&S is Doug Nicoll, director of technical services and the microbiologist who drove the SQF certification process. Mold and bacteria are givens, “plus by having people in the rooms, you’re producing aerosols that can contain contaminants,” he says. With HEPA filtration, Nicoll is assured of fewer than 100 particles per cubic meter of air in the packaging zone. To further

‘Think like a bug’ Birds, rodents, insects: 20 years ago, pests were dealt with only when a problem manifested itself. Today, food manufacturers are much more proactive in dealing with them, “and that’s a huge shift,” according to Greg Baumann, director of technical services at Atlanta-based Orkin Inc. The first rule of pest control is to “think like a bug,” says Baumann, “and where they are going to come in.” But too many companies focus their efforts on raw materials storage and fail to consider the many points of entry. He advises clients to start from the outside and work in, beginning with placement of outdoor lighting. “Let’s move the fixtures away from the building and shine the light toward the plant.” Sodium vapor draws flies and moths, but the variety and volume attracted by mercury vapor is much greater. Light in the red spectrum is invisible to flying insects, but “try selling that to the engineering people,” Baumann laughs. Bakeries often rely on air handling systems to mitigate explosion risks from flour dust, venting the air through a gooseneck on the roof and providing “a nutritious food source for birds, rodents and insects.” A solid sanitation schedule can help mitigate the risk. Blue-light traps are a popular interior defense, but oftentimes they are placed near a glass door. “Don’t make the light

44

May 2011 | Food Engineering | www.foodengineeringmag.com

` Outdoor illumination can contribute to indoor pest problems when light standards are affixed or adjacent to a building’s exterior. A better approach is placement of light fixtures away from the building, so flying insects keep their distance. Source: Orkin Inc.

traps visible from the outside,” he advises. Keeping doors and windows closed is obvious, but the same attention is not always paid to loading docks. “Rodents can literally jump onto a loading dock,” Baumann warns. Clear spaces under load levelers are an open invitation to rodents. He suggests administering a pencil test: If an opening is large enough to poke a pencil through, it’s large enough for a rodent to squeeze by.

Imprecise water application on bread dough caused a significant QC problem for a leading bakery. Application of too much water caused the dough to rise unevenly while too little water resulted in the sesame seeds not sticking properly. In both cases, the baked bread had to be scrapped. PulsaJet® spray nozzles controlled by an AutoJet® Model 1550 Modular Spray System provided the precision required to ensure bread quality. The spray controller adjusts the flow rate of the nozzles based on line speed. The proper volume of water is applied uniformly even when conditions change. The hydraulic PulsaJet nozzles with positive shut-off prevent dripping, misting and overspray.

The results: UÊ-VÀ>«ÊÀi`ÕVi`Ênn¯ UÊ>ˆ˜Ìi˜>˜ViÊ̈“iÊÀi`ÕVi`ÊÇx¯ UÊ œÃ̏ÞÊVœ“«ÀiÃÃi`Ê>ˆÀÊiˆ“ˆ˜>Ìi` i>À˜Ê“œÀiÊ>LœÕÌÊ̅ˆÃÊ܏Ṏœ˜Ê >˜`ʅœÜÊÜiÊV>˜Ê}i˜iÀ>ÌiÊÀiÃՏÌÃÊ vœÀÊޜÕÊ>ÌÊëÀ>Þ°Vœ“ÉÀiÃՏÌÃ

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9

SANITARY PLANT DESIGN

Aesthetics of cleanable walls and floors Conventional wisdom holds that a food plant’s ceiling, walls and floor are forever, or at least until the space is taken out of production. But FDA and USDA’s dimmer view of evidence of corrosion could mean premature retirement for many plants, given the prevalence of steel in many wall and floor materials, including reinforced concrete. Concrete’s advantages have made it a common material for ceilings, walls and floors, but its porosity and poor chemical resistance and tensile strength can result in premature failure in a food-production environment. Rebar or wire mesh usually is added as reinforcement, and once moisture reacts with the steel, oxidation occurs. In years past, manufacturers tried to mitigate the problem with coatings, but many were poorly engineered and improperly applied, leading to blistering, cracking and other evidence of bond failure. Today’s resins are able to deliver a seamless, more durable, washable surface that can extend a plant’s useful life and bear up to the close scrutiny of a customer

improve outcomes, a catalytic converter that employs ozone adds a kill step. It replaced an activated carbon filter “that loaded very quickly and deteriorated after a couple of weeks,” says Nicoll. Ozone

MECHATRON® 3-A Loss-In-Weight Feeders

audit or regulatory inspection, according to John Durig, global market development director for food & beverage at Clevelandbased Sherwin-Williams Protective and Marine Coatings. Outgasing and moisture-related bond failures soured many food companies to polymer floor and wall coatings in the past, Durig concedes, and coatings unable to handle the food acids and thermal shocks that can cause pinholes and delamination are to be avoided. But today’s breathable resins can overcome those issues. If the right coating is applied, manufacturers like SherwinWilliams will warranty them for three years and, in some cases, up to five, provided a qualified contractor does the installation. “It’s no longer adhesion but a chemical bond,” he says. “People are moving to a more cleanable surface, without grout lines,” Durig adds, leading some companies to coat existing wall tiles and acid-brick floors with resin coatings. “There is technology available to create a chemical bond between a glazed tile and our coatings,” he maintains.

gas has proved very effective in reducing odors from onions, he adds. Another defense against airborne contaminants is a system in which UV light reacts with titanium dioxide to create free hydroxyl radicals.

Quick, easy product changeover and food safety

SolidsFlow™ USDA Vibratory Feeders

With today’s stringent food safety standards and the need for greater process efficiency, having to disconnect up-stream hoppers and flex connectors to access a feeder during changeover or general maintenance doesn’t cut it. Neither does improperly designed components that trap material. Address those problems and other food safety related concerns with Schenck AccuRate’s non-process side disassembly and easy wash-down feeders. • OPERATOR FRIENDLY CONTROL PACKAGES FOR FEEDING AND WEIGHING SYSTEMS. • FIELDBUS, HMI, ACTIVE X, WIRELESS, AND GROUP CONTROLLER.

www.accuratefeeders.com PLEASE CALL: (800) 558-0184 OR (262) 473-2441 • E-MAIL: [email protected] See Food Master, p. 3

46

See Food Master, p. IFC 14

May 2011 | Food Engineering | www.foodengineeringmag.com

Schenck AccuRate is a unit of Schenck Process

©2009 Schenck AccuRate

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SANITARY PLANT DESIGN Ultraviolet is being considered as a food safety requirement for elements of refrigerated air systems, suggests a white paper by Munters Corp. “Consideration needs to be given to incorporating a UV light section in the condensation control system as a means of meeting this increasingly likely industry requirement,” write experts at the Amesbury, MA desiccant supplier. As relationships with major retailers and other food companies expand, Nicoll expects to integrate new technologies to maximize product quality and shelf life. Customers are asking about the potential for cross-contamination of allergens through a plant’s air system. “People are raising good questions,” he says, “and we don’t have all the answers.”

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Evolving standards Before joining Burns & McDonnell, David Dixon helped design the Kinston, NC pork processing facility of Smithfield Foods. The plant, which opened in 2006, incorporated best-in-class approaches to sanitary design, including highly pressurized air and room-to-room control. Dedicated water supplies and wastewater systems that were isolated from each other and never crossed were installed, adequate space was provided around equipment for 360° access, stainless steel platforms were installed, and minimal contact between floors and materials was a consideration. Still, the needs of production dictate a game of tradeoffs. Fryer placement is an example: Minimizing moisture and heat in the air is necessary for sanitation, but a cooking unit works against that. “If you can

put the fryer in another room, then you don’t have to remove the heat, but that’s always a tricky design,” says Dixon. Similarly, plants used to be designed for linear flow, with wide-open areas between receiving and shipping. Today, zones of separation are the rule, an approach that reduces the risk of cross-contamination but works against efficient product flow. “Companies recognize they must improve food safety,” notes Hixson’s Adler. “They’ve looked at better personal hygiene and gowning. Now they’re moving to the more capital-intensive projects like air handling.” Greenfield projects provide a blank canvas to incorporate the best approaches to sanitary design. Unfortunately, most professionals must work with the plant they have, and upgrading an older building to meet evolving sanitary standards is difficult, especially for smaller manufacturers that lack the capital access enjoyed by major food companies. Fortunately, there are many opportunities to upgrade sanitary design without major expenditures. The key is to step back, evaluate the existing facility’s strengths and weaknesses, and begin prioritizing. ❖ For more information: David Dixon, Burns & McDonnell, 630-272-1677, [email protected] Jim Adler, Hixson, 513-241-1230, [email protected] Darryl Wernimont, POWER Engineers, 904-318-7186, [email protected] Greg Baumann, Orkin Inc., 404-888-2783, [email protected] John Durig, Sherwin-Williams Protective & Marine Coatings, 800-524-5979

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GREEN MANUFACTURING

Software tracks sustainability Take action now to reduce consumption by monitoring energy usage in real time. ` Wayne Labs, Senior Technical Editor

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on’t consider being sustainable altruistic. Today, consumers expect businesses to show respect for the environment by decreasing waste and greenhouse gases and saving electricity and water. But more important to processors, sustainable management of resources means a better bottom line and more profitability. Conserving resources is good for everyone. Saving water, for example, is becoming especially critical. According to the World Health Organization, less than 1 percent of the world’s fresh water (or about 0.007 percent of all water on earth) is readily accessible for direct human use. But being able to track the sustainability of an operation requires careful planning and the right tools. Assuming a manufacturer has the right hard-

ware in place to track processes, adding software tools to monitor the sustainability of a plant is a lesser issue than adapting a plant that has few or no sensors or instrumentation in place. Of the software tools dedicated specifically to monitoring utilities and energy consumption, processors will find lots of choices. Some software tools can also calculate energy saved in units of greenhouse gases (GHGs). Getting on bandwagon When Darryl Wernimont, POWER Engineers market specialist for the food and beverage industries, worked for a large A&E/C (architectural and engineering/construction) firm, his experience with food processors was that in 2001, one out of 100 clients typically asked about green/sustainable initiatives. Ten years later, practically every processor he meets wants to discuss sustainability. Processors realize, says Wernimont, “green” is no longer a unique differentiator in consumers’ eyes; it has become an expectation much like safety and security. “We still find that many firms are collecting sustainability data manually—and largely for the purpose of reporting to external stakeholders,” says Sean Robin` Some energy management systems, such as Iconics Energy AnalytiX, can show process and building energy usage, consumption per week or month and a derivation of the environmental impact in terms of CO2. Source: Iconics.

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GREEN MANUFACTURING

` An energy flow diagram is a map of where a plant’s utilities are consumed, and it should set the baseline for the application of any energy management software and hardware. Source: POWER Engineers.

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son, GE Intelligent Platforms food and beverage industry manager. While this does create awareness of overall usage, it doesn’t provide the base of data needed to drive understanding of what controllable factors a producer can address to reduce its consumption. “Many manufacturing companies are still in the early stages of developing or implementing their sustainability strategies,” says Jay Zoellner, EPS president and CEO. “This is new territory for most of them, and many are struggling to achieve the level of results they set in their targets.” Zoellner says three barriers, identified in a 2010 Pew Research Study, make it tough to get started; these are organizational, informational and resource obstacles. The right software—coupled with a supplier that can provide consultation and supporting hardware— can make the task of overcoming these barriers much easier. So why should processors invest in an advanced energy management system? There are two big reasons, says Bob Zak, Powerit Solutions North America general manager and president. First, it enables them to meaningfully reduce energy costs and carbon emissions without reducing production capacity. Second, according to Zak, an advanced energy management system produces benefits on multiple operational levels: • Increased visibility into operations via improved monitoring serves as an early warning system, e.g., an increase in energy use may predict an asset failure. • An energy management system monitors the entire facility and controls not only core production equipment, but also ancillary or support loads that were not previously automated. • An energy management system can unite islands of automation to leverage coincidental operation and minimize energy use.

May 2011 | Food Engineering | www.foodengineeringmag.com

• An energy management system helps processors meet customer demands for and corporate commitment to sustainability measures. However, selecting the right supplier isn’t a small task. In 2004, Del Monte Foods received funding from State Technologies Advancement Collaborative (STAC) to install an enterprise energy management (EEM) system at one of its plants. Del Monte asked Lawrence Berkeley National Laboratory (LBNL) to evaluate EEM vendors. LBNL developed a specification framework and selection criteria and procedures to find the right supplier. The lab started with a list of 27 EEM vendors, and then pared it down to four by reviewing vendors’ websites, doing phone interviews and sending out questionnaires asking vendors to detail their abilities in connectivity, metering, integration, data security, data visualization and analysis, and reporting capability. Requests for proposal (RFPs) were sent to the four. One vendor couldn’t provide the requested features within budget, and the web demonstrations of two other vendors were somewhat unfocused on EEM features as a pre-developed tool, but the winning vendor’s demonstration covered most of what Del Monte requested, showed flexibility for future software expansion and was well developed.1 Do your homework Once the discussion takes the direction of tackling sustainability issues and purchasing software solutions, processors need a starting point that will ultimately drive the identification of potential software solutions, says Wernimont. “That starting point has to be an energy audit that will help determine what actually is going on and establish a baseline from which the application of monitoring and control (software and hardware) can be applied.” With the knowledge gained from an energy audit, processors can take actions to achieve measurable sustainability. These actions will drive the implementation of PLCs, PCs, software and instrumentation to achieve sustainable objectives. Wernimont outlines what the results of an energy audit should include: • Map existing energy distribution and use • Identify areas of use (efficient & inefficient) • Allow the isolation of specifics • Drive areas of evaluations (monitoring, control, regeneration, alternative energy, etc.) • Provide details to apply hardware, software and instrumentation to control and monitor

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GREEN MANUFACTURING

` Demand spikes of power to start equipment simultaneously can raise an energy bill significantly; some power companies are placing penalties on out-of-control demands. A smart system can shift these demands so they’re not happening all at once. Source: Powerit Solutions.

• Provide a baseline of comparison • Create a blueprint for other facilities. Processors need to review the five basic utilities that consume energy. These are often called WAGES (water, compressed air, natural gas, electricity and steam). However, trying to tackle sustainability issues in all WAGES categories at once may not be practical or fit in with the budget, as Del Monte discovered in its project. “We offer engineering and consulting services that can help manufacturers design an information-enabled automation architecture that draws WAGES resource consumption data from across the facility and takes action on that information to reduce consumption,” says Phil Kaufman, Rockwell Automation industrial energy management business manager. Energy consultants help manufacturers make sense of resource consumption data and identify more opportunities for improvement throughout the facility. Once the early work is done, Rockwell applies a four-stage methodology— known as Industrial GreenPrint. The methodology employs many of the supplier’s software solutions to help manufacturers gain better control over how they use WAGES resources, helping reduce the burden of utilities costs on profitability and lessen the risks associated with external factors affecting resource price and supply. Look for pressing issues The starting point for a processor is to determine its baseline energy and resource usage—to make sure it has the ability to monitor and understand the usage coming from its primary pieces of equipment, says Zoellner. Second, the processor needs to determine what success means in its eyes, be it a reduction in energy intensity (e.g., BTU of energy used/gallons of product produced) or a fixed percentage of annual cost. Third, the manufacturer needs to determine

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if it is willing to allocate resources to achieve the goal, he adds. Once there is clarity around these points, the next step is to start analyzing the information coming from plant equipment to see what processes, equipment or production shifts account for the bulk of energy and/ or water use. Food and beverage companies are focusing within the plant and on water usage and treatment, energy savings, waste reduction, and process and workflow optimization, says Tom Muth, Parsec director of marketing. For example, processors are trying to determine if a plant is paying too much for electricity at peak demand rates, understand the distribution of energy usage and determine how much energy is being used and wasted while the plant is not in active production. Processors are also taking a look at the energy impacts on workflow and SKUs, and they’re trying to determine what assets need to be retired when more efficient solutions can be found. While a lot of low-hanging fruit is obvious—leaking air lines and water pipes, sections of unattended warehouse lighting left on, overuse of rinse water, utilities running at full capacity during weekend shutdowns, etc.—there are others some processors fail to address, according to Steven Hawkins, Stellar director of automation services. Both ammonia and air compressors and other systems with “high availability” such as 24-hour systems like steam, HVAC and air balancing systems need to be considered according to actual needs. “There’s still a lot of unpicked fruit within production operations because without the right tools, processors can’t see it,” says Robinson. “Our customers have consistently realized water and energy reductions of 10 to 20 percent when they begin to invest in measurement and improvement programs.” The hard dollar savings associated with energy and water usage reductions can offset the costs for both metering and software in less than a year. “That’s fruit worth harvesting,” he adds. Although Amy’s Kitchen was signed up with PG&E for a demand response program that could save the processor money in utility bills, it never put monitoring equipment in place. According to Bert Pires, Amy’s Kitchen director of engineering, “We were never able to do anything because we didn’t have a way to measure information, and we couldn’t make the necessary changes manually.” Working with Powerit, Pires installed a system to track the heavy demand caused

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GREEN MANUFACTURING can operate standalone or as part of a larger SCADA/ control system, says Iconics Vice President of Marketing Gary Kohrt. Iconics’ Energy AnalytiX software collects, aggregates and normalizes metered data, and shows meaningful data on the consumption of electricity, gas, steam, fuel oil, etc. The software derives carbon emissions data and can present all the above data by hour, day, month and year. One of the key areas where sustainability is affected is the amount of time it takes to make important sustainability decisions due to delays in accessing the right data needed to make those decisions, says Kevin Rutherford, Software Toolbox Inc. brand manager. In most cases, when there is a problem, increased time to change a process or even stop production only multiplies the additional cost involved.

` EPS xChangePoint software, working in conjunction with hardware, lets operations staff get a handle on specific energy users in the plant and make intelligent choices about their operation. Source: EPS.

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by the compressors of two spiral freezers and other heavy loads. After installation of the Powerit software and hardware, Pires noted the system “added quite a bit to our savings. In fact, when factoring in incentives, demand response is probably the largest component.” Amy’s utility was able to secure a rebate of 88 percent of the cost of the system, which has decreased demand by about 44 percent while saving approximately 10 percent of billed monthly power. As shown above, software tools cannot only find high-energy users, they can also manage and schedule them to cut operating costs, says Hawkins. Ammonia compressors once were not very compatible with variable frequency drives (VFDs), but that has changed, and because VFDs are now small in size and affordable (compared to 10 years ago), most motorized equipment can be controlled and scheduled, adds Hawkins. Software in conjunction with a few sensors can make sure that three air compressors are not running when only one is needed, and it can also soft-start the idle compressors sequentially so peak demand penalties are not incurred from utilities. For processors that aren’t automated, the good news is that SCADA software for monitoring doesn’t have to cost $100,000 to $150,000. According to Hawkins, a good monitoring system that can provide both historical and current data is available from suppliers like Rockwell, GE, Schneider and Siemens, and a basic system can look at 50-100 points, which is ample to get a good start on monitoring energy usage. SCADA software providers are releasing bundled solutions for energy management applications that

May 2011 | Food Engineering | www.foodengineeringmag.com

Beyond low-hanging fruit “Most tier-one processors have done or are well under way to address ‘low-hanging fruit’ projects,” says Yves Dufort, global industry solutions director, Invensys Operations Management. But to tackle the next wave of opportunities, processors need to have a better understanding of operational data. By doing this, they can modify some of their operating procedures to optimize energy and water usage while reducing their carbon footprints, he adds. While processors can easily account for water usage in the process, sometimes water—like compressed air—can be lost in leaks. With water, if the leak is in an underground pipe, it may not be so obvious. One solution from Siemens uses hardware (temporarily installed acoustic sensors) and Siemens Siwa Leak Control system software. The system continuously checks for leaks, and can pinpoint their location. The software uses statistical methods and a model-based, network-wide mass balance of water. Besides energy waste in compressed air systems, Dufort suggests CIP, baking and drying are all candidates for reducing the overall energy intensity of operations. Likewise, reducing water usage per unit of output leads to reduced energy usage because the unused water doesn’t have to be pumped, cleaned, heated, cooled or treated on its way to the public treatment center. Dufort reports that a Northeast sugar confectionery processor is currently rolling out energy management software to measure the energy intensity for its products. Using the software, the processor can promote its social responsibility to consumers, and understand how successful its sustainability strategies are. Several benefits can be achieved by improving combustion control in boilers and other applica-

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GREEN MANUFACTURING ` Siemens Siwa LeakControl system is a software system used in conjunction with standard flowmeters and the temporary, snap-on acoustic sensor (shown) to monitor pipes continuously for leaks. Source: Siemens Industry.

tions requiring firing, says Bruce Jensen, Yokogawa Corp. of America manager systems marketing and technical support. Improved sensor technology using tunable laser diodes in conjunction with control software improves safety, reduces emissions and increases uptime. In addition, the increased accuracy of these devices allows tighter control, using less energy in fired heater applications. Jensen suggests another, perhaps esoteric—but strategic—way of indirectly reducing energy requirements. In

the pharma industry, discussion centers around the realtime release of products, which can apply to food as well. If processors could get faster results from lab tests, product wouldn’t have to be quarantined as long, so less warehouse space would be needed to accommodate the sitting products. With refrigerated/frozen products, energy use to chill the product would also be reduced—not to mention transportation costs. Any reduction in time to make decisions about the status of a product provides real-time control benefits. In addition, predictability in process and predicting/ accounting for variability in real time creates closer-to-spec products, which significantly reduces recycling or rework, adds Jensen. For processors wanting to express GHGs related to CO2 and NOX stack emissions, energy monitoring software should be able to calculate GHGs on actual consumption, not just invoiced energy purchases, says Dufort. And when it comes to compressed air and steam, Dufort says the system should be able to record the cost to produce (fuel, water, electricity) and the cost to consume throughout the plant.

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Packaging can play both direct and indirect roles in a processor’s sustainability program—direct in the sense that using less packaging saves money, and indirect in that packaging involves the use of recyclables or non-petroleum-based materials. Tracking the use of packaging, however, can be complex and potentially hard to justify cost-wise, says Dailey Tipton, FirstCarbon Solutions global leader, sales and marketing. “Tackling initiatives such as reducing package material, manufacturing more reusable and refillable packaging and producing more lightweight, biodegradable plastics can bring worthwhile ROI and also solve regulatory issues,” adds Tipton. FirstCarbon (provider of ghgTrack software) is working with Associated Packaging Technologies, which supplies CPET ovenable containers to the food industry, to create a GHG emissions inventory, produce auditable GHG footprint reports, align reporting to the international standards of the Carbon Disclosure Project (CDP) and help APT reduce emissions across its global supply chain. Energy and/or environmental monitoring software can be used in many ways to improve efficiency and save energy. While every processor has different priorities for achieving a more sustainable operation, each should start with the basics (low-hanging fruit) and, before going for the more esoteric areas, look for a consultant who has experience with other processors. A system integrator may be a good place to

start. A local utility is also an option since, in many cases, its consultants will be knowledgeable and affordable, and will often have the connections and know-how to find state or federal grants. ❖ For more information: Sean Robinson, GE Intelligent Platforms, 434-978-5000, [email protected] Bob Zak, Powerit, 206-467-3030, [email protected] Tom Muth, Parsec Automation Corp., 714-996-5302, [email protected] Darryl Wernimont, POWER Engineers, 208-288-6100, [email protected] Jay Zoellner, EPS, 714-957-1087, [email protected] Kevin Rutherford, Software Toolbox Inc., 704-849-2773, [email protected] Phil Kaufman, Rockwell Automation, 414-382-4337, [email protected] Steven Hawkins, Stellar, 904-260-2900, [email protected] Yves Dufort, Invensys Operations Management, 514-421-4210, [email protected] Gary Kohrt, Iconics, 508-543-1500, [email protected] Bruce Jensen, Yokogawa, 770-254-0400, [email protected] Dailey Tipton, FirstCarbon, 888-826-5814

References: 1

Naoya Motegi, David S. Watson and Aimee T. McKane, LBNL, “Enterprise Energy Management System Installation Case Study at a Food Processing Plant,” 2006 (http://industrial-energy.lbl.gov/ node/362). Pub. # LBNL_STAC.

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See Food Master, p. 68 www.foodengineeringmag.com | Food Engineering | May 2011

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CONVEYING SYSTEMS ` This right-angle transfer unit from Dematic diverts cases to order assembly and then shipping. Belts pull the cases onto the diverter; rollers rise up and send them on to the next conveyor. Source: Dematic.

The vital lifeline of production Every process needs connectivity—the right “circulation system” to provide optimum hygiene, flexibility, fast changeovers and ease of maintenance at the lowest possible cost. ` Jaan Koel, Contributing Editor

C

onveyors play a vital role in food production. They are the circulatory system of a food plant, delivering raw materials to the processing front end, up to and through the packaging machine or filler, and then downstream to staging, accumulation, case packing, palletizing and final shipment to the customer. If the circulatory system breaks down, everything breaks down. Robust design, washdown capability, affordability, accumulation, flexibility, quick changeover times and automation are the mainstays food producers look for in conveyor solutions. Today, orders are becoming more complex. Larger retailers take dedicated pallets because they deal in large volumes and have the space to store products before putting them on shelf. Smaller operators,

however, ask their suppliers for mixed pallets of disparate products because storage space is limited, and volumes aren’t as high. Every production environment is unique and defined by a number of factors—product type, package type, processing speed, filling speed, space constraints, budget, automation requirements, accumulation needs and more. To get the right solution at the lowest cost, it’s best to consult an expert. Accumulation, buffering are key factors According to Jim Streblow, vice president of sales and marketing at Wisconsin-based Nercon, a vital capability of every conveyor system is accumulation. “More and more producers are focusing on that aspect,” he says, and for good reasons. Manufacturing machines in a production line are bound

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CONVEYING SYSTEMS to have problems from time to time. Be it the unscramber, the filler, the labeler or case packer, a line can be kept alive with accumulation and buffering zones that allow production to continue while short stoppages occur. “Is accumulation the heart of the production line’s circulatory system? In a way, it is. Accumulation and buffering can provide the breathing needed to feed machines when unexpected problems occur, and protect efficiency and profitability,” notes Streblow. Short delays can happen any time on just about any type of equipment. Priming the labelers, cartoners or case packers are planned delays, but unplanned delays can happen too, such as an incorrectly oriented package jamming in a wrapper. And

these short delays can add up. For example, six 10-minute stops in an eight-hour shift translate to one hour of lost production. If machines shut down at different times, which they almost always do, productivity losses can peak to 40 percent or more at times during the day. “Add potential spoilage of product to lost production time, and the effect can be huge,” says Streblow. “A plant design with effective accumulation will help protect the bottom line.” Choosing the right type of accumulation and buffering solution for each product and application can be a critical factor in longterm performance and competitiveness. Accumulation occurs on conveyors in the spaces between the packages. Controls are added to conveyor systems to allow for

Bearings make the world go ‘round It’s been said that love makes the world go around. Bearings do too. Their absence or failure can cause conveyors and other food plant machinery to shut down—one of the reasons bearing factories were such a high priority target for Allied bombing raids in World War II. In a plant, conveyors connect everything, but it’s the bearings that enable the conveyors to run, the motors that drive them to operate and the reducers to control speed. The main enemies to bearing life and performance in a plant are moisture, contamination, corrosion (rust) and inadequate lubrication. Product Business Manager Kyle Sobke at BaldorDodge Bearings in Fort Smith, AR says average bearing life in food plants, which are typically characterized by tough washdowns, can be limited substantially by the harsh environment. “When bearings fail, part of the plant has to be shut down. So it’s not just the cost of the replacements you need to consider, but more importantly, the lost productivity.” According to Sobke, Baldor-Dodge bearings used in food plants can provide improved performance and longer life. “Our approach is to offer higher-quality products that save the user costs associated with frequently replacing failed bearings.” Two main factors contribute to this—the Quad Guard sealing system and the Max-Life Cage design. The Quad Guard system features a geometrically designed triple-lip seal along with a rubberized flinger (a disc with wide-angled spokes) that physically prevents water and caustic washdown fluids from entering the inner workings of the bearing. The Max-Life Cage, a specialized retainer that holds the rolling elements in place within the ball track, is geometrically designed to keep the lubricating grease from being washed out. “The standard lubricant in a food plant is H1 food-grade grease, which doesn’t stand up as well as non-food-grade grease to moisture, hot-pressure spraying and caustic chemicals,” notes Matt Frady, Baldor-Dodge roller bearing product

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` Baldor-Dodge washdown bearings feature a patented QuadGuard sealing system and Max-Life Cage design to keep grease in and fluids out. Source: Baldor-Dodge.

business manager. “That’s why we’ve put such an emphasis in building a robust sealing design to protect this more delicate grease from liquid exposure.” Baldor-Dodge does a business with OEMs that build new conveyors, as well as directly with end-users that want to retrofit or upgrade their existing lines. Bearing housings are generally built to standard dimensions across the industry, so replacing one brand with another is usually easy to do. “We completed a retrofit for a large meat producer in Nebraska in early 2010, and when I visited that plant a year later, our bearings were still running fine,” says Sobke. “This facility went from replacing ball bearings every two to three months to realizing more than a year’s worth of life out of their ball bearing solution. With the number of mounted bearings in a plant ranging from the hundreds to the thousands, the goal is to get as much life as you can before you have to replace any of them.”

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CONVEYING SYSTEMS ` The screening section of the Triple/S Dynamics Tex Flex Vibratory Conveyor was designed to remove loose pieces that may enter the product stream from unsealed pouches. Source: Triple/S Dynamics.

Utilizing conveyors for an accumulation solution typically costs less than a machine solution because transport conveyors are needed between equipment anyway. Simply adding controls and perhaps additional conveyor length may meet the accumulation and buffering needs of some production lines. However, when the amount of accumulation is greater than the spaces between the products, investing in a storage device or accumulating machine is necessary.

accumulation as well as buffering—the breathing—of product transport on the line. Accumulation can be designed into a single lane, as well as into multi-product wide lanes depending on application specifics such as the product, line speeds and machine capacities. Belt speed determines buffering capacity. For instance, if the product is 12-in. long, and the rate of output from the filling machine is 60 products per minute, a 60-ft. long conveyor operating at a speed of 60 ft. per minute (fpm) will be continually full, offering no buffering capacity. If the belt speed is increased to 120 fpm, the line can accumulate 30 products at any given time during a downstream interruption.

Accumulation machines In addition to accumulating conveyors, there are a number of other accumulation machines on the market that provide greater capacity and more sophisticated product handling. Accumulation equipment can be first-in-first-out (FIFO), or first-in-last-out (FILO). First-in-first-out is useful where more sensitive products need to be coded and tracked on a case-by-case basis before final shipment. First-in-last-out is used where close tracking is not required. Many types of accumulation equipment deliver products randomly or somewhere in between FIFO and FILO, such as: • Alpine system: Alpine machines elevate or lower products on a single product-wide vertical serpentine conveyor and, with controls, can provide both accumulation (between product spaces) and buffering capabilities.

New conveyor systems speed changeovers at Campbell Soup Infinite adjustability, quick and repeatable changeovers, and ease of use were some of the key items a Campbell Soup plant in Paris, TX was looking for in the conveyor solution for a new beverage production line it installed in early 2010. The line produces V-8® vegetable juices, V-8® V-Fusion beverages and V-8® Splash juice beverages in five different PET bottle sizes, ranging from 12 to 64 ounces. “We were looking for a side rail system that could provide rapid changeovers between the current package sizes, and possible new ones that we may introduce in the future,” says Campbell Soup Group Engineering Manager Bob Gibson. “We ended up using a system that is interconnected by shafts and adjusted using guide blocks, zone by zone, by a hand crank. It’s easy and precise to go from one package size to another,” says Gibson. “Adjusting corners is as easy as the straight sections.” According to Gibson, to optimize conveyor performance, particularly for PET bottles, it is critical that lubrication is maintained to reduce friction between the belt and the containers.

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` Campbell Soup V-8® V-Fusion beverages in 12-ounce PET bottles move down the line on a new conveyor with adjustable rails. Source: Campbell Soup.

Rather than using the standard soap and water approach, which results in wet floors and corrosion on conveyor bearings and other parts, he and his team decided to use a dry lubricant. “All it takes is a couple of seconds of spray every hour to reduce pressure on the line,” explains Gibson. “It’s more sanitary, there’s no mess to clean up, and you save money by not having to install drip pans.” The following vendors were used on this project: BarryWehmiller Companies Inc., Septimatech Group Inc, Ecolab and Intelligrated.

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CONVEYING SYSTEMS ` The Allpax conveyors shown here use specially designed stainless retort baskets. Conveyor systems are modular and use common frames, shaft sizes, bearings and other components, no matter the size or configuration of the line. This reduces spare parts and maintenance for processors. Source: Allpax.

if the main line goes down,” he says. “It’s generally a more expensive route, but the payback is in production efficiency.” NCCAS is an integrator that uses packaging equipment from all the major suppliers. “Our approach is to pre-engineer a line. We assemble all equipment, wiring and automation inside our production facility; test the customer’s product in a series of trial runs; and then deliver the complete package for reassembly in the customer’s plant. This process minimizes installation and start-up times— from a month or more to a week or less,” Mauger says. • Drum spiral conveyor: The drum spiral conveyor utilizes a wide chain that has the ability to accommodate rows of product for accumulation. It can also be controlled to respond to fluxes in downstream production. • Vertical accumulator: Products are backed up in rows and then are “parked” on a flight and indexed up until the accumulator is full. The vertical accumulator uses a small footprint compared to the volume benefits. • Recirculating accumulation table: Two wide belts traveling in opposite directions cause a recirculating motion of products on this accumulation table. Products flow randomly out of the discharge area. • Bidirectional accumulation table: When the main conveyor senses a back-up, the wide belt on the bidirectional table located adjacent to it begins to move perpendicularly to the main conveyor, and accumulates products. When the back-up is cleared, the belt reverses direction and discharges products back into production. • Variable length accumulators: Offering true buffering capabilities, variable length accumulators are designed with an expandable and contracting product path that is controlled to respond to minute surges in production. • Serpentine accumulators: Built on a vertical accumulation concept, these accumulators offer variable length accumulation in three dimensions. The product travels on rows and makes use of vertical space. But simply adding accumulation machines and buffering conveyors into a production line isn’t enough to fix inefficiencies. The machine layout and conveyor configurations need enough space to allow for each machine’s threshold. Conveyors must also be properly specified to feed and discharge accumulating equipment. And buffer zones must be completely cleared; downstream equipment should always run faster than upstream equipment. This not only creates the required buffering capacity, but also enables accumulated packages to be purged as required. Kevin Mauger, president of NCC Automated Systems (NCCAS) in Souderton, PA, says introducing redundancy is an effective alternative or complement to buffering. “This involves adding extra conveyor and packaging lanes that can take product 66

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Modularity and flexibility Dematic of Grand Rapids, MI has been in the conveyor business for 72 years. Dematic engineers and builds modular conveyors that can be mixed and matched according to processor requirements, and then assembles them on-site. Once complete, the modular concept allows optimum flexibility. “In the past, it was typical for a company to set up a conveyor system and use it for years with few changes,” notes Ken Ruehrdanz, industry manager for Dematic. “Today, however, we may implement a conveyor system, and in less than a year, the user will want to modify it because of a change in business requirements, which supports the need for modular conveyors.” The modular concept also provides capital cost savings, because equipment does not have to be specially engineered. “Everything is built around a universal side frame,” says Ruehrdanz. “If you wanted to change divert points in your conveyor system in the past, there were multiple diverters built with completely separate designs. Today, all diverters/sorters are made from common parts and universal side frames that make changes much easier, faster and less costly.” For example, a section of roller conveyor may need to be converted to belt surface conveyor, or a transportation conveyor to an accumulation conveyor. “These modifications can be made without the need to remove or replace sections of conveyor. Instead, by utilizing many of the existing components and using the same side channel foundation, a new system configuration can be created more easily,” he explains. Food companies are introducing new products—and increasing or decreasing volumes—faster than before. Some changes are driven by economic needs—reducing the size of a frozen entrée, for instance, to drive cost per unit down while keeping the same price point. Others are driven by sustainability—switching from corrugated to film overwrap, for instance, to reduce package volume and waste, or switching from one package format to another to achieve easier, more economical recycling. Dematic’s automatic storage and retrieval system (ASRS) employs stacker cranes that take loads and store them on racks for later use. When products are needed for an order,

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CONVEYING SYSTEMS the stacker crane retrieves the load and sends it to the point of use. Through PLCs and HMIs, operators know exactly where everything is at any given time, which is important not only for production and reporting, but also for traceability purposes. Dematic also has a system it calls “Multi-Shuttle”—essentially a sequencing staging buffer. It stores a number of different product SKUs in a racking system, then releases each load as required for order fulfillment, palletizing or shipping according to each day’s orders from customers. Upgrading Conveyor systems have a long lifecycle, and to extend their life further and avoid new installation costs, a number of options are available. First, a conveyor can be modernized by simply changing the rollers. Worn rollers can produce a lot of noise and damage the side frames. Replacement rollers have universal dimensions and fit into the side frames of almost all conveyor brands. Replacing mechanical sensor rollers with electronic versions allows lighter weight cartons to be conveyed, reduces sound levels and improves carton control. Meanwhile, line shaft conveyors can be upgraded to motor driven rollers (MDRs) as a retrofit. MDR conveyors offer sleep mode (saving energy), accumulation mode, variable speed control and improved carton flow. Pulley motor assemblies, meanwhile, can be replaced with a motorized pulley, which is essentially

a drum motor that dramatically reduces energy usage, sound, parts and maintenance. When DelGrosso Foods of Tipton, PA, one of the oldest and largest family-owned producers of pasta sauce in the US, wanted to increase capacity by 50 percent in its existing plant, it hired Nercon to provide field verification, line layout, engineering and installation. The high-speed expanded line (500 jars/min.) starts with a new high-speed, pressure-less, single-file conveyor handling empty glass jars. A live drum spiral conveyor feeds a rotary jar rinser and three heat tunnels to pre-heat the glass. The jars are then filled with hot pasta sauce and sent through a horizontal head space and cap sterilizer. The conveyor uses a cylindrical drum that assists in driving the chain, providing low belt tension, increased elevation and increased speed. The full-jar conveying system is engineered to demand-divide and mass flow into two spray coolers. Out of the coolers, jars are recombined using mass flow conveyors with multiple bidirectional tables. A high-speed pressureless single file conveyor delivers full jars to labeling operations. A final bidirectional table is utilized to buffer case packaging operations. Nercon also provided the automated controls and numerous menu-driven HMIs. “To increase our production speeds, it was critical to have a smart accumulation plan for this whole line,” says Vice President Joe DelGrosso. “We needed to prevent short-term line stoppages that can kill efficiencies. Nercon’s mass flow conveyors and bidi-

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rectional tables allow us to continue to run our filler and cooling operations while short-term stops in labeling and case packing are resolved. We designed the labeling and case packaging operations with additional capacity to handle the full production rate and work off the accumulated backlog. This line has improved our overall capacity by 50 percent through higher filling speeds, good accumulation planning and effective line design.” Innovation, changeovers and hygiene Some companies are stretching the envelope to satisfy their customers. One of them is Triple/S Dynamics of Dallas, TX, which historically had focused on the production side with a Slipstick Horizontal Motion conveyor, as well as other vibratory conveyors for bulk food. But after a major client ran into a problem on the other side of the filler, Triple/S Dynamics went to work to modify its technology. The vibratory conveyor the company provides on the processing side is called TexFlex. The customer had a problem, however, with the 3- x 3- x 1/2-in. pouches that weren’t spreading out well enough into a monolayer for cartoning. Furthermore, the pouches were occasionally contaminated by food contents escaping from pouches that weren’t sealed properly. Triple/S modified its traditional TexFlex unit to create a specially designed post-filling vibrating conveyor to spread the pouches in the manner the customer needed. The unit has springs under the conveyor trough and a rotary electric vibra-

tory motor to shake the pan at a predetermined angle and stroke. Immediately after being spread out into the required monolayer, the pouches pass over a screen bed so any loose food pieces fall through and don’t wind up in the cartons later in the line. “It worked like a charm,” notes Triple/S Sales Engineer Tim Talberg, “and has potentially added a new offering to our portfolio.” Beyond equipment efficiencies, speeding up changeover times is becoming increasingly important in food plants, and conveyor manufacturers provide a number of solutions. “Many producers run multiple packages in a day, and when they switch to a new package size, they want to be able to reset their machines and conveyors as quickly as possible,” says Nercon’s Streblow. Options range from simple tool-less adjustable guide rails up to automated rails operated by optically controlled PLCs or an HMI. “More automation is able to reduce labor costs, and all the big 100 food companies are going in that direction,” he explains. Allpax of Covington, LA supplies retort systems and dedicated conveyors to connect the different parts of the lines it manufactures. A critical concern of producers they supply is retort bypass—accidentally sending raw product to labeling. To prevent this, Allpax developed an automated Allen Bradley-based tracking system called Alltrak that controls and tracks basket status from start to finish. “Our conveyor systems are all modular. What changes is the basket size,” says Allpax General Manager Greg Jacob. “No matter the size or number of our baskets, we use the same shaft sizes,

See Food Master, p. 68 www.foodengineeringmag.com | Food Engineering | May 2011

69

CONVEYING SYSTEMS

the same bearings, shaft sprockets and chains. This allows users to inventory a common set of parts for their entire plant. For them, it simplifies maintenance.” One might think that in smaller applications this could result in expensive overkill. Jacob notes, however, when looked at from an overall perspective, savings in lead time,

labor, maintenance and common spares outweigh the cost of being modular. A l lpa x uses Eurodr ive motors, known for their gear reducer design. Shafts are manufactured using an alloy called Silvaloy for optimum durability and electroless nickel plating for corrosion resistance. Lines feature Martin

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sprockets, a common brand, and Hitachi Perfect Coat chain. Dorner Mfg. Corp. of Hartland, WI has three levels of hygiene for food plant applications—AquaPruf® and AquaGard®, which are both stainless steel conveyors, and DustPruf®, an aluminum frame conveyor. DustPruf conveyors include SmartSlots™, which feature flat sides rather than T-slots for attaching stands and accessories, such as sensors, metal detectors and more. “The problem we found with T-Slots in particular applications is they can potentially catch dust, food particles and other debris,” s ay s Mar ke t i ng Co m m u n i c at i o n s Director Jay Schoenwaelder. “The flat sides of a SmartSlot™ eliminate potential build-up, while maintaining all the functionality and flexibility of a T-slot. Plus, the side of the frame can be easily and effectively cleaned.” AquaPruf provides the highest level of hygiene with completely stainless steel welded frames that can be washed down entirely and eliminate catch points for dust and bacteria growth. AquaGard also offers many hygienic features, but uses bolts in some areas that are welded on the conveyors. The bolts, however, are kept clear of the food zone. This system has become particularly popular in bakery applications. End-user demands are changing, and producers and their conveyor suppliers have no choice but to follow suit. Every process needs connectivity—the right “circulation system” to provide optimum hygiene, flexibility, fast changeovers and ease of maintenance at the lowest possible cost. ❖ For more information: Jim Streblow, Nercon, [email protected], 920-233-3268 Kevin Mauger, NCCAS, [email protected], 215-721-1900 Ken Ruehrdanz, Dematic, [email protected], 877-725-7500 Kyle Sobke, Baldor-Dodge Bearings, [email protected], 864-281-2238

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T E C H U P DAT E : MOTORS & DRIVES Kevin T. Higgins, Senior Editor

` Servo power systems have followed their induction-motor counterparts in offering washdownready motor options. Stainless steel housings make servo drives compatible with conditions found in processing areas, not simply packaging departments. Source: Beckhoff Automation LLC.

Kinetic evolution

`

Power transmission technology is in flux, and that adds up to a wealth of options for food and beverage manufacturers.

M

ass production is gradually giving way to the Age of Customization. The shift is evident in motor and drive technology. The days when manufacturers’ processes were dictated by narrow power options are gone. Food and beverage companies have committed themselves to meeting the highest global standards in food safety and hygienic production while also pursuing worldclass machine performance. They are pushing suppliers to modify off-the-shelf equipment to meet the particular needs of food production, including optimized OEE and machine reliability. Whether they need electronic variable speed drives or mechanical power, food engineers can pick from a wide assortment of production-ready options.

The availability of stainless steel motors is one example. A rarity 10 years ago, stainless steel induction motors have become de facto standards in poultry production. Automation firms are following their mechanical brethren by introducing stainless steel versions of drives that can stand up to moisture and are air tight. Lean principles compel suppliers to engineer platforms that support multiple variations, depending on the end-user’s needs. Andy Hansbrough, vertical marketing manager-packaging at Radford, VA-based Kollmorgen, estimates more than one million variations of the firm’s drive systems can be delivered. “Design engineers are savvy fellows and know exactly what they want,” he says. “To be innovative and meet their needs, we’ve pursued

www.foodengineeringmag.com | Food Engineering | May 2011

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T E C H U P DAT E

` Technician Scott DeVizio of Stainless Motors prepares a 400hp, watercooled electric motor for testing. Besides shrinking the motor’s overall size, water cooling can boost efficiency to close to 100 percent and reduce bearing wear in high-stress conditions. Source: Stainless Motors Inc.

the lean philosophy and pride ourselves in providing custom-like solutions off the shelf.” For evidence of mechanical innovation, look no further than Albuquerque, home of Stainless Motors Inc. Company Founder and Chief Engineer John C. Oleson never expected his firm to be more than a niche supplier, building the occasional stainless AC motor to meet specialty applications for pharmaceutical manufacturers. Instead, the motor builder rode a demand wave that has made it the preeminent US supplier of those power systems. If crude oil reaches the $140 a barrel prices it commanded three years ago, interest should spike for one of Oleson’s most interesting engineering achievements: a water-cooled stainless motor (see “Water cooled and stainless,” Food Engineering, February 2009). The first of these motors was 400hp

and powered ammonia compressors at Beef Products Inc. in South Sioux City, NE. Bearing failure with conventional motors was a frequent event in summertime, when demand pushed RPMs as high as 4,000. In autumn, Oleson’s first water-cooled motor marked its third anniversary of continuous performance. The purified water that cools the engine is piped to boilers and for other waste-heat applications, pushing motor efficiency to a theoretical 100 percent. The incoming water lowers the operating temperature approximately 50°F, accounting for the bearing’s longevity. But the upfront design work and piping requirements add cost, and the recent economic collapse and temporary easing of oil prices cooled commercial interest. “If you go by the MBA rulebook and say you need an ROI in three years, it’s a pretty tall bill,” acknowledges Oleson. “But at five years, it absolutely does pay back.” Interest in the motors is picking up, and Oleson anticipates an order to build a 700hp water-cooled motor. Motors R Us The motor world’s biggest change this year occurred in the boardroom, not the R&D lab, when Baldor Electric Co., North America’s largest NEMA motor supplier, was acquired by the Swiss automation conglomerate ABB Ltd. (see related story below). Other than basing the combined motors and drives operations in Fort Smith, AR, little is clear of what

Power transmission’s 800-lb. gorilla The familiar and the new always share an uneasy coexistence, and transition occurs in fits and starts that obscures change. This is evident in the trend away from mechanical to electronic power. Variable speed drives ultimately will replace electric motors and mechanical power transmission, though no one living today will be around when the transition is complete. Induction motors remain the power source of choice in industry and likely will remain so for the foreseeable future. But automation companies are placing their bets on servos, which explains Rockwell Automation’s decision in June 2006 to divest itself of the power systems group composed of Dodge bearings and gears and Reliance electric motors.

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Among the potential suitors rebuffed by Rockwell before the eventual sale to Baldor Electric Co. five months later was ABB Ltd., reliable sources say. Milwaukee-based Rockwell simply didn’t want an automation competitor to acquire its old-school power group. All of which added extra punch to January’s acquisition of Baldor by ABB. More immediately, the deal filled a gaping hole in the electric-motor lineup of ABB, which did not have any NEMA-rated motors. For Fort Smith, AR-based Baldor, it armed its sales force with perhaps the most comprehensive line of power options available, regardless of whether end-users prefer electronic or mechanical solutions.

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T E C H U P DAT E ` The evolution of drive systems for conveyors can be seen in this display from SEW-Eurodrive. At left, Chris Wood of SEWEurodrive eyes a motor and converter assembly with a belt to deliver power to the conveyor. Premium and super-premium motors (center) combined the power train in a single unit, resulting in sanitary enhancement. The newest generation (below) has on-board electronics and starting torque three times higher than the continuous torque, resulting in much lower power requirements to drive the system.

the merged operations will mean in terms of technical change. “The low-voltage drives business is a great enhancement,” says David Steen, an AC motors product manager at Baldor, quickly adding, “We don’t see AC and DC motors going away or being replaced.” While Baldor includes electronic drives and controls in its lineup, the company’s bread and butter long has been NEMA motors, particularly energy-efficient units. Demand for pre76

May 2011 | Food Engineering | www.foodengineeringmag.com

mium efficiency motors has grown about 25 percent in recent years, Steen reports, and new requirements from the Department of Energy should spur additional growth. US standards for energy efficiency are the highest in the world, he points out, and Baldor continues to push the innovation envelope. The firm hopes to introduce line start permanent magnet induction motors later this year, Steen says. The efficiency improvement over general-purpose motors can be negligible, however, particularly as the motor’s size increases. The payback comes when a systems approach to gearing and motors is taken. Calculating the return on mechanical drive-system efficiency requires number-crunching skills, however. “That’s a significant issue we continue to deal with, day in and day out,” says Steen. The company sponsors webinars and educational forums to help plant personnel explain to upper management why investing in premium power systems is a smart business move. Factoring in energy consumption plays to the total cost of ownership calculations being made by many industrial firms. Those calculations are necessary if companies are to upgrade to mechatronic drive systems. “There’s a lot more than just installing more energy-efficient motors when it comes to optimizing your system,” observes Chris Wood, industry account manager at SEW-Eurodrive Inc., Richmond, VA. Upgrading a motor might yield a 10 percent efficiency gain; upgrading the entire system can mean a 30 to 40 percent improvement, he points out. To illustrate, Wood cites the performance gains created with SEW’s Movigear, the company’s mechatronic option that incorporates controls with the motor and drive in a single unit. “Movigear is just catching on in North America,” he says, though European manufacturers have been transitioning to it for several years. A fully automated bus system is a prerequisite. The motor is only a few points more efficient than the prior generation, but double-digit reductions in energy costs can be realized, and overall efficiency gains are even higher. The decentralized drive technology also facilitates more compact construction, requiring about a quarter less space. The components come at a higher cost, but SEW estimates the premium is recouped within two years on the basis of electric costs alone. The system most often is used to power conveyors, and Movigear’s high starting torque is a big advantage in the start-up phase compared to conventional systems.

` If any gaps in Baldor’s paint-free and washdown-ready motors, gears, drives, inverters and other power-transmission solutions existed, they were filled when the manufacturer was acquired by ABB Inc. Source: Baldor Electric Co.

Hydrophilic servos Flexibility and speed are critical needs in packaging, and “that’s where servos thrive,” observes Adam Shively, a servomotors product manager at Milwaukee-based Rockwell Automation. “Upstream, it’s more of a continuous process, and continuous duty doesn’t lend itself to servos.” Nonetheless, the automation supplier has developed a line of stainless servomotors to meet the hygienic requirements of in-process machinery. The MP-Series motor is available in three International Protection Ratings, including the rigorous IP69K, which certifies resistance to 1,200psi washdown. Considerable cost is added with stainless, and dissipation of waste heat can be an issue. Beckhoff Automation LLC, Burnsville, MN, complements its stainless options with food-grade AM3000 synchronous servomotors. An FDAcompliant white coating that meets IP67 standards adds to the motors’ cost, allows Joe Martin, packaging and converting sales manager, but the markup is a fraction of what stainless housings command. “We were able to alter the molecular composition of the paint so that it adheres to the metal and doesn’t peel or flake,” adds Martin. As servos have shrunk in size and become faster and more affordable, their applications have expanded beyond pure packaging, he continues. “We’re seeing a blending of processing and packaging,” with machines combining multiple steps, such as slicing, filling and sealing. Because it is a sealed unit, a servo sucks in moisture when it cools, and that presents a problem for the onboard electronics. Beckhoff is upgrading controls technology in its drives through a partnership with Fertig Motors GmbH, a start-up firm headed by the founder of Elau AG, which was acquired by Schneider Electric in 2004. See Food Master, p. IFC 14 www.foodengineeringmag.com | Food Engineering | May 2011

T E C H U P DAT E

Pumps and fans account for a major share of industrial power consumption, but those machines seldom are outfitted with energy-conserving components such as variable speed drives, acknowledges Ivan Spronk, product marketing manager at Schneider Electric United States, Raleigh, NC. Instead,

sophisticated drives like Schneider’s Altivar 32 are applied to applications such as packaging machines. “Because it is electronic solid state, it is easy to turn on and off ” when not engaged in value-added production, says Spronk. More importantly, “with AC variable speed drives, you can slow equipment www.amerivap.com

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A portable steam cleaning machine specifically designed to clean and sanitize continuous flat conveyor belts.

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Improve Safety, Health and Quality Inspection Results Reduce System & Line Down Time Save Money: Cut Labor & Chemical Costs Drastically Reduce Water Consumption Eliminate Water Waste Reduce Toxic Waste: Be More Eco-Friendly & Reduce Disposal Costs

First. . . Best . . . Different

AmeriVap® Systems, Inc. | Phone 404.350.0239 | Fax: 404.350.9214 Email: [email protected] See Food Master, p. 10

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Higher standards of sanitation are now possible in an environmentally responsible way.

The Houdini Brush and Jet Systems work tirelessly insitu, sanitizing as they clean without chemicals, and with very little water usage.

down when you don’t have to run at full speed,” saving significant amounts of energy over the machinery’s useful life. Many of the new drive’s improvements relate to reduced wiring and minimizing panel space. A more compelling advancement is the kind of simplified programmability that threatens the long-term need for controls engineers. For example, an option card that is easily attached to the drive delivers Ethernet connectivity without any code writing. Users can use Boolean to customize the drive to a specific machine application while saving on installation components. Spronk likens it to the network capability of smart phones. Kollmorgen’s Hansbrough credits the consumer electronics industry for pushing automation suppliers to deliver more compact and economical drives and easier-to-program controls. “With innovation, you have some failures,” he concedes, “but innovations developed for that market are migrating to industry and delivering technology that is more flexible, more reliable, and comes at a lower cost.” Package proliferation forces manufacturers to change over packaging machines more frequently as they try to “run as close to demand as possible,” adds Hansbrough. That in turn has opened the door to more automated power sources that can be changed over with the push of a button. At the same time, suppliers like Kollmorgen have developed motor-drive combinations with software in the drives’ electronics, eliminating the need for a controller and thereby lowering costs. The end-user always is right, and if stainless motors and drives are specified, power transmission specialists are ready to oblige. But if anodized aluminum or two-part stainless steel epoxy paint is acceptable, manufacturers can have an hygienic design that doesn’t break the bank, suggests Dan Throne, business manager-food & beverage at Bosch Rexroth Corp., Hoffman Estates, IL. If the motor is positioned outside the operating environment, stainless

is a redundancy that only adds cost. Standard aluminum motors are used in an aseptic filler using Rexroth drives, Throne notes. Last fall, Rexroth introduced a “near motor” servo drive that mounts directly onto a machine, near the motor and away from the control cabinet. The configuration reduces cabinet size and lowers cooling and wiring costs. The integrated drive ranks as a niche product, with applications skewing to light-duty work in the fractional-horsepower range. Another specialty offering is explosion-proof motors that are required in starch molding for candy. Motor sparks must be isolated from airborne starch particles to control a potentially explosive process. Stainless Motors also is catering to the need for explosion-proof motors designed specifically for food. Bolts that hold the units together typically are on the exterior for added strength, “but that is exactly what our customers do not want,” says Oleson. After a 62-week approval process, Stainless Motors secured UL approval for an explosion-proof motor that “looks just like a NEMA frame motor,” he says. “How we pulled it off is the subject of our patent.” An Oleson innovation that was too arcane to secure a defensible patent involves a positive pressure lubrication system for gearbox roller bearings. When a worm gearbox is mounted vertically, as is the case with many mixers, the upper bearings and gears can become starved of lubrication, particularly at low RPMs. Oleson’s invention relies on a cam-driven pump off the output shaft to fling lubrication upward. “With every revolution, a squirt of oil goes to the top,” he explains. “I think it’s very important in preventing premature failure.” Strictly speaking, gear lubrication is neither motor nor drive technology, but the invention exemplifies the many ways power transmission systems continue to improve and evolve. Just as the equipment itself is associated with motion, the technology itself is kinetic. ❖

Adam Shively, Rockwell Automation,

For more information: David Steen, Baldor Electric Co., 479-646-4711

414-382-2000, [email protected]

Joe Martin, Beckhoff Automation LLC, 952-890-

Ivan Spronk, Schneider Electric United States,

0000, [email protected]

919-851-0720

Dan Throne, Bosch Rexroth Corp., 847-645-3749,

Chris Wood, SEW-Eurodrive Inc., 804-740-2269,

[email protected]

[email protected]

Andy Hansbrough, Kollmorgen, 540-633-3405,

John C. Oleson, Stainless Motors Inc.,

[email protected]

505-867-0224, [email protected]

www.foodengineeringmag.com | Food Engineering | May 2011

79

The he industry’s oonly nly pre-fifilled ed ard bound catalog listing listing equ uipment, hard equipment, upplies and services to th he ffood ood and annd supplies the everage industry is only a phone ccall all away. awaay. beverage ndor listt oorr w ade Noo need to work with an incomplete ven vendor wade through Master comprehensive rough hundreds of consumer listings online. TThe he Foodd M aster is thee most comprehens reference Operations, Engineering Engineering, M Manufacturing executives. eference source for Plant Operations anufactturing and Packaging exec

To order your personal copy, call Ann Kalb at 248-244-6499 or go to www.foodmaster.com

SPECIAL ADVERTISING SECTION

LI TE R AT U R E & P R O D U CT R E V I E W Bulk Bag Discharging System

DynaShear Inline Dual Stage, High Shear Mixer & Disperser

SacMaster is a bulk bag discharge system designed specifically to include the important features and functions identified by bulk bag manufacturers and food processors. Bag tensioning, hoist or forklift loading, height adjustability and the patented “Posi-Flow” agitation system make SacMaster® the right choice for discharging flour, sugar, cocoa powder, and a wide range of other bulk materials. Additionally, the SacMaster® is optionally available with load cells for loss-of-weight batching applications.

DynaShear inline high-shear mixers will blend, dissolve, deagglomerate, disperse, and emulsify a wide range of fluids and semifluids, and are particularly effective for wetting out powders into a liquid. Its unique head design creates excellent shear and flow providing droplet size reduction down to 2-3 microns.

®

Admix, Inc. 234 Abby Road Manchester, NH 03103 www.admix.com 800-466-2369 / 603-627-2340 Email: [email protected]

For additional information on Schenck AccuRate products, contact us at 800-558-0184 by fax at (262) 473-4384 or visit www.accuratefeeders.com.

Xtreme Steam by AmeriVap Systems

Ashworth

The Xtreme Steam unit from AmeriVap Systems is a portable dry steam vapor unit that offers totally organic cleaning and sanitizing. The unit reduces water consumption, increases sanitation standards and is ideal for cleaning and sanitizing packaging/production equipment, electrical control panels, conveyor belts, robotics, motors, scales, drains, chains, and so much more. AmeriVap also introduces the Houdini Automatic Conveyor Belt Cleaner and Sanitizer, which is powered by Xtreme Steam generators.

Ashworth’s new website provides on-demand access of conveyor belt information for many specific requirements. With over 900 pages, the user-friendly interface provides a simple way to find features, benefits and specifications for a wide range of applications. Ashworth - The Conveyor Belt Experts Phone: 1-800-682-4594 [email protected] www.ashworth.com

Phone (404) 350-0239; Web www.amerivap.com

Spray Nozzle Video

Bel-Ray Company, Inc. Bel-Ray’s industrial lubricants deliver top-quality made in the USA products to industrial customers worldwide. The No-Tox line of food safe products feature NSF H1 certification and are Kosher and Parve approved. Bel-Ray’s superior performance leads to greater machine life and increased production capabilities. Bel-Ray Company, Inc. PO Box 526 Farmingdale, NJ 07727 [email protected] Bimba Manufacturing

The HydroWhirl® S spray nozzle video from BETE Fog Nozzle helps visualize slotted rotating spray nozzles. These nozzles clean more quickly and use less water & pressure than static tank washers. HydroWhirl® S rotary spray nozzles provide 360º coverage and are designed for long service life. BETE Fog Nozzle, Inc. 50 Greenfield Street Greenfield, MA 01301 T (413)772-2166 F (413)772-6729 www.bete.com [email protected]

Sanitary Mixing and Blending Brochure Food processing environments put a diverse number of demands on your designs. That’s why whether it’s a simple clamping application, or a complex controlled closed loop bottle filling solution, Bimba is dedicated to delivering products that meet USDA requirements, improve efficiency, and reduce costs. And as always, when you work with Bimba, customer commitment comes standard.

Ross manufactures a complete range of mixers for virtually all mixing, blending and dispersion requirements within the food processing industry. Our full line of laboratory and production sanitary mixers is presented in this brochure. To receive your free copy or inquire about trial/ rental units, call or email Ross today.

Bimba Manufacturing Monee, Illinois 60449-0068 Telephone: 708-534-8544 • Fax: 708-235-2014 Email:[email protected] Technical Assistance: 800-44-BIMBA www.bimba.com

Charles Ross & Son Company 710 Old Willets Path Hauppauge, NY P: 1-800-243-ROSS E: [email protected] W: www.mixers.com

www.foodengineeringmag.com | Food Engineering | May 2011

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SPECIAL ADVERTISING SECTION

LI TE R AT U R E & P R O D U CT R E V I E W Reserve your FREE 2011/12 Cole-Parmer® General Catalog Select the latest fluid handling, laboratory research, industrial process, and electrochemistry products to help you get your job done! More than 2,600 pages feature brand names such as Masterflex®, Oakton®, Polystat®, and many more.

Cyclone Belt Washer Cyclone C-RH Belt Washer Rotary Head Belt Washer for Open Mesh Belts

SPRAY HEAD MOUNTED ON SPIRAL INFEED

CATCH PAN MOUNTED UNDER SPRAY HEAD

OPTIONAL LINEAR HEAD FOR SOLID BELT APPLICATIONS

PORTABLE CART MOUNTED TO SPRAY HEAD

Cyclone Rotary Head belt washing applications include Spiral Conveyors, Freezing Tunnels, Meat Fryers/Ovens or any other type of belt that allows for drainage. Reduce down time, remove allergens, increase belt life and save water and labor with a Cyclone Belt Washer. Designed for maximum cleaning effectiveness, the Cyclone’s rotating spray head – with speed and pressure adjustment – cuts and removes stubborn soils from both the top and the bottom in one pass.

Reduce down time, remove allergens, increase belt life and save water and labor with a patented Cyclone Belt Washer from Douglas Machines. Designed for a wide variety of open mesh spiral conveyors, freezer tunnels and oven belts, the portable Cyclone spray head features high pressure rotating nozzles to cut and remove stubborn soils from both the top and the bottom in one pass.

Comes with a portable cart that allows you to move from one belt to another for quick clean up. Consider an optional “Air Blast” Blower with portable air knives to aid in drying, an optional catch pan to collect water for convenient routing to drain and optional Linear Spray Head for solid belt applications.

To reserve your copy, call 800-323-4340 or visit ColeParmer.com/8280.

HIGH-LIFT BOX/CONTAINER DUMPER Boxes and other containers loaded at floor level are sealed against a discharge hood, elevated and tipped, mating the hood outlet to a gasketted inlet port on vessels 6 to 10 ft (183 to 305 cm) above the plant floor. Accommodates containers 36-48 in. (915-1220 mm) on a side, and 39-44 in. (9901117 mm) in height. Flexicon Corporation 1-888-353-9426 [email protected] www.flexicon.com

Better Blending in Less Time with Fristam Stop wasting your valuable time and money on outdated, oversized, or underperforming mixing systems. Fristam’s Powder Mixer provides quick, high-performance blending of wet and dry ingredients into a fluid stream. Fristam’s Powder Mixer: • Dramatically reduces process times • Produces consistent batches • Devours lumps, clumps, and fisheyes • Cleans in place • Eliminates ladder climbing • Handles flow rates to 375 gpm, powder induction rates to 600 lbs/min Fristam Pumps USA • www.fristam.com/usa • 1-800-841-5001

Manual and Automated Sanitary Valves Inline Industries manufactures a complete line of sanitary ball and butterfly valves for your food processing applications. Valves are available in Full Tube Port dimensions and can be supplied in various finishes and pipe connections. Actuation packages are readily available from stock. Inline Industries, Inc. 4701-A Littlejohn Street Baldwin Park, CA 91706 (800) 568-8998 [email protected] www.ballvalve.com

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• Works With or Without Hot Water MEET TODAY’S HIGH STANDARD OF CLEANLINESS AND SANITATION FOR BOTH CUSTOMERS AND REGULATORS. • Reduces Spiral Belt Tension STANDARDIZE YOUR CLEANING PROCESS. SAVE VALUABLE WATER, LABOR, ENERGY AND CHEMICAL EXPENSE. • Cleans Without Degreasers or Caustics • UL/CSA/CE Approved Control Panel R EDUCE DOWNTIME. INCREASE PRODUCTIVITY • Cleans Metal or Plastic Belts • Does the Work of Two Men

• Uses just 3 - 4 GPM at 1500 to 2000 PSI • Portable Spray Head & Cart • Removes Fats, Sugars, Oils & Allergens • One Year Parts Warranty

Douglas Machines Corp. 2101 Calumet Street • Clearwater, FL 33765 P: 727-461-3477 E: [email protected] W: www.dougmac.com

Vector Conveyor with Phantom Metal Detector For maximized system performance, Fortress offers the complete all-in-one detection solution – a Phantom Metal Detector with an integrated Vector Conveyor system. These sanitary systems are designed for easy cleaning, IP69K certified, and meet the strict requirements of applications demanding the maximum hygienic protection in their processes. Applications include: • Fresh, chilled & frozen foods • Packed & loose products • Bakery

• Confectionery • Ready meals • Snacks

• Meat & Poultry • Dairy • Ingredients

Please visit Fortress Technology at: Interpack in Germany, Booth # F04-13 • PackEx in Canada, Booth # 1231 Fortress Technology Inc. Tel: 1-888-220-8737 or 416-754-2898 • [email protected] www.fortresstechnology.com

Hapman Releases Six-Page Capabilities Brochure FLEXIBLE SCREW CONVEYORS Helix™

Convey bulk powders and solids in less space, less time. Economically convey bulk powders and solids up to 25 cfm (.708 cmm).

Select from a range of hoppers in standard and custom sizes as well as flanged inlets or charging adaptors.

Avoid product contamination with completely enclosed conveyor.

Disassemble conveyor in minutes for cleaning with exclusive T-handle couplings (optional on most models).

Minimize material flowback with optional UHMW-PE center core.

Keep high-moisture or sluggish materials flowing with optional ribbon agitators.

Fit under low ceilings. Optional rightangle drive reduces necessary headroom.

Spend less money conveying materials, too. • Excellent for batch, intermittent and continuous conveying of free- and non-free-flowing bulk materials. An economical solution for conveying powders, crystals, pellets, friable material, flakes, granules and much more. • Simple, yet rugged construction keeps costs low, reliability high. A helicoid screw rotates inside a fixed tube. Fewer components minimize maintenance. The conveyor’s standard stainless steel construction stands up to a continuous flow of abrasive materials. (Carbon steel and polyethylene models also available.) Optional mobile base lets you use one conveyor in multiple locations.

A true performance guarantee ensuring your Hapman equipment achieves the specific results it was designed and manufactured to deliver. And if you need technical support, call us. We are available 24/7.

• Convey materials over distances up to 80 feet (24.4 m) and discharge heights up to 40 feet (12.2 m). An optional mobile base provides a discharge height of 12 feet (3.66 m).

A new, six-page capabilities brochure offers an overview of Hapman’s comprehensive conveying, feeding and bulk bag handling solutions for processors. Literature, including updated sales sheets can be downloaded via www.hapman.com in both standard and A4 formats. Print copies in standard format can be requested by calling 1-800-427-6260.

• Easy to clean. Disassemble conveyor in 5 minutes for thorough washdowns.

© 2010 Hapman. All rights reserved.

Take a free TEST DRIVE! Contact: [email protected]

www.hapman.com

Hapman [email protected] 800-427-6260

SIZE/DENSITY SEPARATOR REMOVES FINES AND CHAFF FROM GRAINS A Vibro-Air ™ Size/Density Separator employs vibratory screening and airflow to simultaneously remove fines and chaff from grain products. Material fed through a port on the unit’s hood cascades over a series of strategically placed internal trays, and ultimately onto a vibrating, fine mesh screen that moves on-size material in controlled flow patterns toward and through a discharge port at the screen’s periphery. Kason Corporation +1-973-467-8140 [email protected] www.kason.com

SPECIAL ADVERTISING SECTION

LI TE R AT U R E & P R O D U CT R E V I E W Pneumatic Conveying Components at Your Fingertips – K-Tron Launches New Online Components and Accessories Catalog

Martin Brothers, Inc. Heat Exchangers Martin Brothers stocks all makes and models of nickel scraped surface heat exchangers with a re- chromed inside diameter tube. Martin Brothers re-chromes the tube inside diameter plating to a finished 0.006” thickness. We also provide technical, troubleshooting, custom design and customer services. We are an international supplier and the only company in the world dedicated to remanufactured and reconditioned scraped surface heat exchangers.

K-Tron, a total solutions provider for material handling and feeding systems has recently launched a NEW Online Catalog for Pneumatic Conveying Components and Accessories. The new catalog showcases the extensive range of pneumatic conveying products K-Tron offers and, best of all, provides an easy-to-navigate format for users. The online catalog features comprehensive technical information and detailed images to provide users with a simple and quick platform to find the right solution for their pneumatic conveying needs.

Please check out website, www.teammartinbrothers.com, for available equipment and prices.

K-Tron has defined the leading edge of technology for material handling applications in the process industries. Visit www.ktron.com or email [email protected].

Bag Dump Station:

Mettler-Toledo Safeline The enhanced PowerPhasePRO metal detector delivers unrivalled levels of detection sensitivity and detects even difficult to find non-magnetic stainless steels. Extremely user-friendly, it delivers unparalleled on-line stability for increased profits.

Crafted to meet your bulk processing needs, the bag dump station is designed to easily scalp oversized contaminants from manually dumped bulk materials before entering the processing line. The bag dump station can be constructed to food, pharmaceutical, and other industry standards.

Mettler-Toledo Safeline 6005 Benjamin Road Tampa, FL 33634 813-889-9500 Email [email protected] Web: www.mt.com/safelineus

Midwestern Industries, Inc. Toll Free 877-4-Sizing www.midwesternind.com

SANITARY LUMP BREAKER HAS SIDE REMOVAL SCREENS

Newark Wire Cloth

New Sanitary Lump Breaker with side removal bed screens can be sanitized more rapidly than conventional lump breakers that must be unbolted from upstream and downstream equipment to access bottom-mounted bedscreens. Materials are reduced in size by dual rotors. On-size material exits through apertures in twin bedscreens ranging from 1/32 to 2-1/2 in. (25 to 64 mm) in diameter.

Newark Wire Cloth has made available a SANICLEAN Strainer catalog containing the most complete information on inline and side inlet sanitary strainers and wire mesh overscreens. The inline strainer section contains assembly information, component parts and perforated support cores. The side inlet strainer section contains information on assembly, component parts and support cores. The wire mesh overscreen section includes SKS overscreens, wedge wire strainer elements and filter socks and retaining rings.

Munson Machinery Company, Inc. 800-944-6644 [email protected] • www.munsonmachinery.com

Contact Richard Campbell at Newark Wire Cloth 800-221-0392 or [email protected]

DILBERT™ NEW HORIZONS® in Products for Sanitary Applications Version No. 27 Contains over 180 pages of the latest information on top selling products for the sanitary food, beverage, pharmaceutical, bio-medical and related process markets or lab operations, including the Digital RTD Thermometers with NEMA 4 Enclosures for wash down, sanitary, and marine applications. Omega Engineering One Omega Drive • Stamford, CT 06907 Toll Free: 800-826-6342 • Tel. 203-359-7815 www.omega.com

Perfex Corporation Perfex Corporation has become the nation’s principal manufacturer of unique and innovative cleaning tools designed for controlled environments. Our products are designed to be cost effective, easy to use, as well as heat, bacteria and chemical resistant. TruCLEAN™ Cleaning Systems isolate contaminants to ensure the delivery of unadulterated cleaning agents. Constructed of high-grade stainless steel, TruCLEAN™ Components are easy to maintain and compatible with gamma, ETO and autoclave sterilization. Perfex Corporation 32 Case Street • Poland, NY 13431 Toll Free: 800-848-8483, Tel. 315-826-7471 • www.PerfexOnline.com www.foodengineeringmag.com | Food Engineering | May 2011

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SPECIAL ADVERTISING SECTION

LI TE R AT U R E & P R O D U CT R E V I E W Quickdraft

SEALMASTER ENGINEERED INFLATABLES Quickdraft’s pneumatic systems can safely convey edible and inedible product, scrap hot dog casings, packaging trim, cook-in bags, mechanically deboned meat residue or other material hundreds of feet for further processing or disposal with minimal operator interaction.

Improve processing efficiency with Seal Master Engineered Inflatables. Custom built, fabric-reinforced and fully molded, they are widely used for sealing for close tolerance applications and to fill voids and compensate for irregular surfaces. Actuators, bladders, bags and plugs also featured. Use for mixing, drying, cooling, granulation, coating and other applications. FDA compliant compounds. Designer assistance offered.

Quickdraft 855-VENTURI [email protected] quickdraft.com

SEAL MASTER CORPORATION 368 MARTINEL DR., KENT, OH 44240 Ph:800-477-8436, Fax: 330-673-8242 www.sealmaster.com email: [email protected]

SlipNOT® Metal Safety Flooring

New Expanded Line of Tank Cleaning Equipment

SlipNOT® manufactures slip resistant stainless steel flooring products. Products are registered by NSF International for use in food processing facilities. From floor plates, bar grating, ladder rungs and rung covers, to platforms, drain covers and stair treads; SlipNOT® is the one-time answer for increased productivity and safety. Products are manufactured to specifications.

Additions to the TankJet® line from Spraying Systems Co. include several high-impact tank cleaners for removal of stubborn residues, motorized units that provide a targeted directional spray and compact nozzles for cleaning small containers. Request Catalog 15 and get complete details on dozens of tank cleaning solutions for tanks up to 100’ (30 m) in dia.

SlipNOT® Metal Safety Flooring 2545 Beaufait Street Detroit, MI 48207 ph: 313-923-0400/800-754-7668 fx: 313-923-4555 web: www.slipnot.com

Spraying Systems Co. PO Box 7900 Wheaton, IL 60187-7901 1-800-95.SPRAY www.tankjet.com

More Choices, More Solutions with SPX It’s hard to find a more comprehensive portfolio of processing equipment anywhere else. Many of our designs incorporate patented features and our research and development efforts continue to produce groundbreaking technologies. You’re sure to find answers in the SPX Flow Technology Food and Beverage brochure that will improve plant performance, increase profitability and enhance the value of your brand.

Urschel Engineered to produce continuous precision slices with extensive detail given to key elements throughout the machine, the new E TranSlicer® Cutter joins the production-proven TranSlicer series in the Urschel line-up.

SPX Flow Technology 611 Sugar Creek Road, Delavan, WI 53115 Tel: 800-252-5200 Fax: 262-728-4904 Email: [email protected] www.spxft.com

WENGER ENHANCED SANITARY DRYER The new Wenger Enhanced Sanitary Dryer delivers greater sanitation; less potential for cross-contamination and bacteria build-up; and a reduction in the amount of production time lost due to off-line inspection and cleaning. Wenger Manufacturing, Inc. 714 Main Street Sabetha, KS 66534 1-785-284-2133 [email protected] www.wenger.com

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Contact Urschel for more information: (219) 464-4811, [email protected], www.urschel.com Hygienic Conveyor Belts Wire Belt is the leading manufacturer of open mesh stainless steel conveyor belts, keeping your lines running for over 60 years. Wire Belt offers a variety of metal conveyor belts, extensively used for breading, battering, frying, cooking, coating, dusting, and cooling. All of our products meet USDA NSF/ ANSI/3-A hygiene standards, so you can TRUST you have the cleanest, safest conveyor belt in your plant. Wire Belt Company 154 Harvey Road • Londonderry, NH 03053 (603) 644-2500 [email protected] • www.wirebelt.com

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EQUIPMENT FOR SALE

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The ONLY Company Dedicated to REBUILT Scraped Surface Heat Exchangers s4RUSTONLYTHEOLDEST MOSTEXPERIENCEDEQUIPMENTREBUILDER s2ELYONTHELARGESTINVENTORYINTHEWORLDDOZENSOFMACHINESINSTOCK s#ALLOREMAILFORFREEAPPLICATIONENGINEERINGANDQUOTES PART GET IT ./7 FROM OUR HUGE INVENTORY OF USED AND s$ONTWAITONANYMACHINESHOPTOTRYTOlXYOURPARTGETIT./7FROMOURHUGEINVENTORYOFUSEDAND REBUILTMUTATORS TUBES JACKETSANDMUCHMORE s3ELLUSYOURSURPLUSEQUIPMENTORADVERTISE &2%%ONOURWEBSITE

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EQUIPMENT FOR SALE

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www.foodengineeringmag.com | Food Engineering | May 2011

89

AD INDEX

COMPANY

PHONE NUMBER

Admix Inc.

800-466-2369

35

Inline Idustries, Inc.

Air Blast, Inc.

626-576-0144

34

Inpro/Seal

Allpax

888-893-9277

68

JAX

800-782-8850

20

Amerivap Systems

404-350-0239

78

Key Technology

509-529-2161

65

Ashworth

800-682-4594

5

Martin Brothers

800-652-2532

34

Baldor Electric Company

888-828-4920

75

Material Transfer & Storage

800-836-7068

58

www.bel-ray/com

3

Mobil Industrial Lubricants

www.mobilindustrial.com

BC

Belt Technologies

800-832-2358

70

MPE Group

800-965-6065

10

BETE Fog Nozzle, Inc.

413-772-0846

28

National Bulk Equipment

www.nbe-inc.com/food

Bimba

800-44-BIMBA

12

Omega Engineering Inc.

888-82-OMEGA

2

Breddo Likwifier

800-669-4092

IBC

Opto 22

800-321-6786

50

Buhler Inc.

763-847-9900

27

Perfex

800-848-8483

22

Burns & McDonnell

816-822-3831

43

Power Engineers

888-687-8811

57

281-821-7300

58

Process Expo

www.myprocessexpo.com

32

800-243-ROSS

72

Quickdraft

855-VENTURI

33

Clayton Industries

800-423-4585

32

Reid Supply Company

800-253-0421

77

Cole Parmer

800-323-4340

31

Reiser

781821-1290

16

Demaco

321-952-6600

39

Relco

320-231-2210

6

Deprag Inc.

972-221-8731

48

Schenk Accurate

Dorner

800-397-8664

30

Siemens

Douglas Machines

800-331-6870

26

Specialty Equipment

Bel-Ray

Butterworth Charles Ross & Son Corp.

PAGE

EAGLE Product Inspection (formerly Smith Detection PID)

COMPANY

PHONE NUMBER

38

SPX

888-353-9426

19

Fortress Technology

888-220-8737

Friesen’s Inc.

800-568-8998

79

www.inpro-seal.com

4

46

www.usa.siemens.com/foodbev

53

713-467-1818

18

800-95-SPRAY

24, 45

www.spx.com

IFC

Summit Industrial Products

800-749-5823

36

69

Thermo Scientific

800-227-8891

15

800-955-6058

63

Triple S Dynamics, Inc.

877-542-8010

9

800-841-5001

7

Ultrachem, Inc.

302-325-9880

6

GEA Tuchenhagen North America

866-531-5629

47

Wenger

816-891-9272

14

Hapman

877-314-0733

67

Wire Belt Company of America

603-644-2500

60

www.dairyshow.com

21

Zeppelin Systems

813-920-7434

11

Flexicon Coporation

Fristam Pumps

IDFA

Further information on these companies can be found in the 2010-2011 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.

90

37, 39

800-394-2941

Spraying Systems Co. 877-379-1670

PAGE

May 2011 | Food Engineering | www.foodengineeringmag.com

ENGINEERING R&D Kevin T. Higgins, Senior Editor

Gen II for biofuels

`

Commodity prices and a credit crunch sidelined the first wave of biofuel plants, but process inefficiencies also played a role. The next generation of ethanol producers won’t make the same mistake. Ethanol production from corn rubbed a lot of people the wrong way. Increased demand contributed to higher prices for cereal makers, livestock operators and producers of high-fructose corn syrup, and the use of food for fuel struck many as morally wrong. The sin of inefficiency also contributed to the closings, cancellations and mothballing of many of the biofuel plants: By focusing exclusively on the end product and treating the many byproducts as waste to be sold off as animal feed, the facilities simply did not exploit the economic possibilities of production. Consequently, investors were left with overcapacity (tripled in four years, according to the Renewable Fuel Association) and a building bust (10 plants under construction or expanding as of January, compared to 76 in 2007). However, ethanol production isn’t going the way of New Coke. In January, Agriculture Secretary Tom Vilsack announced $405 million in loan guarantees for three biorefinery projects in Alabama, Mississippi and Florida. The feds aren’t doubling down on ethanol, however: The funding is for integrated biorefineries that use wood chips, solid municipal waste and other cellulosic materials as their raw materials. If

` Kamla Jevons, European business development manager-food & life sciences, Koch Membrane Systems, Stafford, UK. Source: Koch Membrane Systems.

the projects are to attract investors, they also will need to capitalize on the full value of their processes. Second generation biofuel installations are just beginning to emerge from the pilot and demonstration plant stage, and shifting market conditions will have as great an impact as they did on the first generation. But these newer facilities also integrate technologies such as membrane filtration. The basic process—convert starch to sugars, then ferment the sugars to produce alcohol for distillation—is the same, but value will be extracted at key junctures to maximize value and financial returns. And that change in approach is keeping people like Kamla Jevons busy. Jevons is the European business development manager for Koch Membrane Systems (KMS) in Stafford, UK. A graduate of London’s West Middlesex College with a Higher National Diploma degree in electronics engineering, she has been involved with membrane applications for a quarter of a century, the last 10 years with KMS. Jevons has expertise in ion exchange, chromatography and membrane separation, beginning with high-purity water production and extending to fermentation-based products, using reverse osmosis (RO), nanofiltration (NF), ultrafiltration (UF) and microfiltration. FE: Why haven’t Gen I ethanol plants panned out? of disposing of the protein as feed after it’s been denaJevons: Companies that put together the base tech- tured, membrane separation could remove it early in

nology were saying, “Here’s a refinery-in-a-box.” They were based on the petrochemical industry’s approach, and the focus was strictly on the ethanol produced. A chemical engineer is comfortable with centrifuges and evaporation but not with fine separation technologies, so the byproducts were viewed as waste or animal feed. The nearest the first generation plants got to finite separation was water recovery and reuse. There were all sorts of recoverable materials that could have improved those plants’ financial viability. Plant proteins aren’t of interest for biofuel, but instead

the process, when it has more value. Similarly, lactic acid and other organic acids that are byproducts of fermentation can be recovered for use in the production of additives for biodegradable plastics. Those acids already provide a level of biodegradability to polylactide (PLA). They also can provide biodegradability to PET and other plastics. FE: How will membrane separation be incorporated into the new generation of biofuel plants?

www.foodengineeringmag.com | Food Engineering | May 2011

91

ENGINEERING R&D

` Second-generation biofuel plants likely will include ultrafiltration, nanofiltration and reverse osmosis technology to maximize recovery of valuable elements that currently are discarded as animal feed or waste. Source: Koch Membrane Systems.

Jevons: This is an evolving area, and

confidentiality surrounds virtually all of our work, but generally speaking, techniques are being considered to facilitate movement to continuous fermentation, rather than batch. Filtration techniques are being evaluated for their ability to improve recovery, reduce waste and lower energy costs. For example, ultrafiltration can clarify the process stream after conversion to sugars during the saccharification process. Some of the cellulosic biofuel processes use acid/alkali to extract fermentable material from stock such as corn stover. In that case, nanofiltration can be used to recover and concentrate some of the useful sugars like hemi-cellulose, which also is used in the fermentation process. FE: Which regions of the world are leading the movement toward cellulosic biofuels? Jevons: There is activity in every

region, though programs are dependent on what is grown there. In Scandinavia, for example, technology based on wood chips is being developed because that’s their feedstock. There are seven or eight major biorefineries currently operating in the European Union and producing multiple products. A huge amount of money is being made available by the US government 92

for research and investment in biofuels and integrated biorefineries, much of it focused on increasing product recovery, reducing waste, lowering energy costs and improving greenhouse gas profiles. In 2009, the US Department of Energy committed up to $564 million for pilot-, demonstration- and commercial-scale, integrated biorefinery projects. Membrane technology will be part of many of these projects. FE: Can older ethanol plants be retrofitted to add value? Jevons: Nano (NF) and UF can be

inserted into a conventional biofuels process to enhance recovery. A centrifuge is the first clarification step to remove dead yeast cells and proteins. The closest Gen I processes have gotten to fine separation is the insertion of RO after centrifugation and before evaporation, with condensate recycled to fermentation, thereby reducing on-site water usage. FE: How has the technology improved to make it more feasible for use? Jevons: Filtration in water treatment

has experienced perhaps the greatest improvement. Years ago, those membranes had a useful life of 12-24 months. Today, some last four to six years. The technology is well understood. Similarly, the understanding of how NF works is much greater than it was 15 years ago. NF separation is one of my passions. There is no such thing as the ideal NF membrane; they all have different separation characteris-

May 2011 | Food Engineering | www.foodengineeringmag.com

tics and different functions. Perhaps the membranes themselves have not changed dramatically, but the understanding of the chemistry of the membrane and the fluid stream itself has advanced considerably. FE: If separation and filtration are developed for biofuels, might there be some process transfers to food application, such as dairy applications? Jevons: Compared to biofuels and

other industries where filtration and separation are still novel, dairy’s use of membranes is well understood. UF is standard and has gone through a long learning curve. The growing areas in dairy are NF and RO, whether it is for enhancing product-stream processes or for producing new products. In the UK, microfiltration now is being used to cold-pasteurize milk, and NF and RO are being used to produce lowlactose milk or to concentrate other components. FE: Do any comparisons support the contention that filtration technology will save biofuel operators money? Jevons: As a complement to evapo-

ration, RO definitely provides some economic advantages, particularly over time. RO is limited in how much it can concentrate, perhaps 20 percent solids compared to 40 percent with evaporation. But the initial capital costs are lower by about a third compared to three-effect evaporation. Over five years, capital and operating costs are less than a third. ❖

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