Food Engineering February 2011

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FEATURES COVER STORY

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Asset Management: Aligning Man and Machine A coordinated approach to asset management has value for facilities, equipment and the people responsible for both.

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Keep the Gears Running Food-grade lubricants have come of age in performance, but the more compelling reason to make the switch from conventional lubricants is to meet regulatory demands.

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The Case for High Benefit Lighting There’s a lot more to new lighting advancements than just saving money.

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Dry Processing Technology Powder blending facility had dust everywhere—dust that should have been in products, not on floors and equipment.

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32 DEPARTMENTS 8

Editor’s Note

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Calendar of Events

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Manufacturing News Lower foodborne illness rate no accident

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Food Packaging Oxygen sucker meets flow wrapper

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Technology Sourcebook Focus on Case Cartoning, Loading and Unloading

Connect with FE on Facebook www.facebook.com/FoodEngineering

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Ad Lit

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Classified Advertising

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Engineering R&D Separation technology helps researchers isolate components in milk.

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www.foodengineeringmag.com EDITORIAL Joyce Fassl Editor in Chief [email protected], 610-436-4220 ext. 8519 Kevin T. Higgins Senior Editor [email protected], 847-405-4045

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The industry’s only pre-filed hard bound catalog listing equipment, supplies and services to the food and beverage industry is only a phone call away. No need to work with an incomplete vendor list or wade through hundreds of consumer listings online. The Food Master is the most comprehensive reference source for Plant Operations, Engineering, Manufacturing and Packaging executives.

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

FOOD ENGINEERING Volume 83, Issue 2 (ISSN 0193-323X) is 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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February 2011 | Food Engineering | www.foodengineeringmag.com

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February 2011 | Food Engineering | www.foodengineeringmag.com

See Food Master, p. 64

EDITOR’S NOTE

The next Walmart effect: healthier Americans and more customers

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

orrect me if I’m wrong, but I don’t recall a First Lady of the United States who ever wielded much influence on the food and beverage manufacturing industry. But last month, Walmart announced sweeping changes in its product offerings to include more healthy food that’s also affordable. The retailing giant plans to reduce sodium, sugar and trans fat in the products it sells by 2015 and produce a simple front-of-product label to deliver the message to consumers. With Michelle Obama joining Walmart as part of the announcement, it dovetails perfectly with her “Let’s Move” campaign against obesity. S o m e o p p o n e n t s h av e s u g g e s t e d Walmart’s purpose is not to make America healthier, but to shore up its profits. Walmart’s sustainability scorecard transformed the food and beverage industry’s level of social responsibility. With the latest mandate, let’s hope there’s a transformation of American waistlines. Just as sustainability was good for the planet and in many cases manufacturers’ bottom lines, healthier foods

is a positive step in the fight against obesity, regardless of which businesses profit. There’s a new world out there, and it’s causing people to make new choices. Working moms have outnumbered stay-at-home mothers for more than a decade, and these busy lifestyles call for smarter food choices. The rise in obesity, diabetes and other illnesses demands attention now. In the past, I never shopped at Walmart. I preferred to go to one supermarket and one pharmacy chain to make all my purchases, mostly for convenience, but I also questioned Walmart’s business practices. In the current era of pay cuts, job insecurity and rising costs of health care, gasoline and home fuel, today I’m in the check-out line at Walmart, for purely economic reasons. If you don’t like Walmart’s employee practices or anti-union history, you can always buy your groceries elsewhere. Putting aside politics or feelings about corporate actions, I think anything that improves the health of Americans is a step in the right direction. See you at the check-out line. ❖

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

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

February 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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APRIL 2011 3-6: Food Automation & Manufacturing Conference and Expo; Ritz-Carlton, Palm Beach, Palm Beach, FL; Food Engineering, www.foodautomationconference.com 13-16: AMI International Meat, Poultry and Seafood Industry Convention and Exposition; McCormick Place, Chicago, IL; American Meat Institute; 703-259-6118; www.amiexpo.com 19-21: Food Safety Summit; Washington DC Convention Center, Washington, DC; BNP Media; 847-405-4063; www.foodsafetysummit.com

MAY 2011 10-11: TD-NMR Applications in the Food Industry: Compositional Analysis, QC, R&D and Safety; NC State University, Raleigh, NC; Dept. of Food, Bioprocessing and Nutrition Sciences, NC State University; 919-515-2957; www.ncsu.edu/project/foodengineer/ short-course

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`NEWS PLANT OPENINGS & EXPANSIONS Cargill invested $8 million at its Fresno beef production facility for several projects including updates to its food safety efforts and renovation and expansion of some packaging lines. The larger of the two expenditures, $4.2 million, involves the installation of a hideon-carcass wash. A second capital expenditure of approximately $3.8 million involves the renovation and expansion of ground beef packaging lines.

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Riviana Foods Inc. is building a new facility in Memphis, TN that will produce ready-to-serve, microwaveable rice products under the Minute rice brand. The facility will be integrated into the company’s 400,000-sq.-ft. processing and packaging plant at 2314 S. Lauderdale.

Malt-O-Meal plans a $136 million expansion to its Asheboro, NC plant. Expected to be completed in 2012, the project includes the addition of more than 200,000 sq.ft. of production space, two production lines and an 80,000-sq.-ft. warehouse. Giant Eagle, with 228 stores and 160 GetGo locations, has opened a 170,000-sq.-ft. facility in Beaver County, PA to supply processed and packaged food to its stores. Danon’s plant in West Jordan, UT will replace an older, existing water pre-treatment system with a new system. This will allow Danon to increase yogurt production from 145 to 242 tons annually while limiting the effect on the environment.

T

he American Meat Institute was encouraged by the findings of two new papers released by the Centers for Disease Control (CDC), which estimate lower numbers for foodborne illness occur annually than previously thought. CDC reported that annual FoodNet Surveillance monitoring of nine pathogens has shown a 20 percent annual decline in laboratoryconfirmed illnesses. According to the new CDC numbers, 9.4 million illnesses, 55,961 hospitalizations and 1,351 deaths per year are caused by known foodborne pathogens. The data represent the first comprehensive analysis released by CDC since a 1999 paper published by Dr. Paul Mead estimated that known foodborne pathogens caused 14 million illnesses, 60,000 hospitalizations and 1,800 deaths. According to the new estimates, the most illness-causing pathogens are Norovirus (58 percent), nontyphoidal Salmonella spp (11 percent), C. perfringens (10 percent) and Campylobacter (9 percent). The leading causes of death by pathogen are nontyphoidal Salmonella spp (28 percent), T. gondii (24 percent),

` The latest CDC data on deaths attributed to foodborne transmission of known pathogens shows Salmonella as the biggest killer (28% of total deaths) followed by Listeria at 19%. Norovirus accounted for most of the deaths caused by viruses. Source: CDC. (Scallan E, Hoekstra RM, Angulo FJ, Tauxe RV, Widdowson M-A, Roy SL, et al.)

Listeria monocytogenes (19 percent) and Norovirus (11 percent). The paper does not attribute foodborne illnesses to their food sources. CDC said that unspecified agents also cause 38.4 million foodborne illnesses, 71,878 hospitalizations and 1,686 deaths annually. CDC defines unspecified agents as a “group of less understood agents,” which could include mushroom and marine biotoxins and little-known bacterial pathogens. “The new data tell us that our food safety strategies have been working, and we need to sustain our research efforts,” says James H. Hodges, AMI Foundation president. “Even one foodborne illness linked to meat and poultry products is cause for concern, and we will not be satisfied until our food supply is even safer.”

www.foodengineeringmag.com | Food Engineering | February 2011

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MANUFACTURING

`NEWS INDUSTRY & PEOPLE OYSTAR GmbH, a global supplier of packaging equipment technology, announced a restructuring that creates OYSTAR North America, a $250 million company with 650 employees. The SHOULDERS new North American company combines OYSTAR USA, a New Jersey-based sales operation, OYSTAR Packaging Technologies (Davenport, IA) and OYSTAR Jones (Covington, KY). Barry Shoulders, president of OYSTAR Packaging Technologies, has been chosen to lead OYSTAR North America. Gordon Bonfield, President of OYSTAR Jones, has been appointed transition officer to oversee the process of combining the three companies .

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Nestlé has agreed to acquire Kraft Foods’ frozen pizza business in the US and Canada for $3.7 billion in cash. The business includes brands such as DiGiorno, Tombstone, California Pizza Kitchen, Jack’s and Delissio. The 3-A Sanitary Standards, Inc. board of directors named Dr. Ron Schmidt (University of Florida) chair and elected other officers for 2011. Dan Meyer (American Dairy Products Institute) was elected vice chair; Carl Buell (Leprino Foods Company) was elected secretary; and Lou Beaudette (Admix, Inc.) was named treasurer. New members appointed to the board of directors include Ray Dyke (Cabot Cheese Co.) and Jon Gardner (International Dairy Foods Association). Archer Daniels Midland Company acquired all of the outstanding capital stock of Alimenta (USA), Inc. from Alimenta S.A., an international trading company based

February 2011 | Food Engineering | www.foodengineeringmag.com

in Geneva, Switzerland. Alimenta (USA) is ADM’s 50-percent partner in Golden Peanut Company, LLC. Pilgrim’s Pride Corporation’s board of directors appointed William W. Lovette as president and chief executive officer. Lovette succeeds Don Jackson, who is resigning from the company to assume the position of president and chief executive officer of JBS USA, which is majority owner of Pilgrim’s. Campbell Soup Company entered into an agreement with Leeds, UK-based dry food manufacturer Symington’s to launch a range of Campbell’s-branded dry soups and pasta and rice meals in the United Kingdom. David Van Eekeren will become Land O’Frost chief executive officer and president effective immediately. Donna Van Eekeren will continue to serve Land O’Frost in the role of executive chairperson.

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

Oxygen sucker meets flow wrapper

`

For manufacturers who would rather take out the air than add in preservatives, a combination of vacuum and modified atmosphere packaging provides an option.

P

eople’s craving for fresh foods often collides with manufacturers’ need for extended shelf life, forcing companies to either accept high product returns or rely on preservatives. Another alternative is to remove all but trace elements of oxygen prior to packaging. A Swiss machine builder is trying to make the case with North American packagers for the enabling technology. Ilapak Inc. introduced the VacMap in 2006, combining the system with its flow wrapper to draw oxygen from the product itself prior to packaging. “Depending on the product, we can get oxygen levels to the parts per million level,” according to Andrew Axberg, president of Ilapak’s US division in Newton, PA. Since its introduction, nine VacMap systems have been deployed in Europe, with French suppliers of fresh, refrigerated pizzas particularly receptive. Preservatives were out off the ques-

` An oxygen sensor confirms oxygen levels are below 0.2 percent in a product prior to wrapping. Heavier gas surrounds the item during the transfer process. Inset: Fresh pizzas and bakery goods are among the most common packaging applications for the VacMap in Europe, where manufacturers want an alternative to preservatives for extended shelf life. Source: Ilapak Inc.

tion for those firms, and shrink wrapping couldn’t remove oxygen from the crust. As a result, product deterioration commenced when the oxygen migrated from the crust and equilibrated in the package. “People need to want to remove the preservatives from their products and have a really fresh product” to justify a VacMap investment, however, and that has slowed broader acceptance of the technology, says Axberg. For some baked goods, preservatives are a factor in the flavor profile, he says, and manufacturers are loath to fiddle with flavor. On the other hand, a case can be made for high-value products: A test involving coffee cake with a seven-day shelf life demonstrated quality could be maintained for four months by combining vacuum packing with modified atmosphere packaging. Oxygen removal occurs inside chambers that resemble a Cryovac vacuum carousel, though the chambers chambe are in line and move on a racetrack from front to end and back. When the product uc is discharged to the flow wrapper, it is enveloped in carbon dioxide. The heavieren than-oxygen gas prevents reintroduction t of oxygen as the product enters the flow o wrapper. Compared to conventional therw moform machines, the system’s film is less m expensive, and throughput is greater, accordex ing to Axberg. t A single controller using OMAC’s PackML si standard ssynchronizes motion between the vacuum chambers and flow wrapper. “One of the great strengths of PackML is in doing OEE calculations for a line,” says John Kowal, market development manager for B&R Industrial Automation Corp., Roswell, GA. The standardized modes and states in PackML should simplify integration with other machinery and facilitate data acquisition, he adds. ❖ For more information: John Kowal, B&R Industrial Automation Corp., 603-258-0371, [email protected] Andrew Axberg, Ilapak Inc., 215-579-2900, [email protected]

www.foodengineeringmag.com | Food Engineering | February 2011

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

Jolly green babies

T

he Jolly Green Giant, Winnie the Pooh and other licensed characters are cropping up on packages of infant and toddler foods from Beech-Nut Nutrition Corp. Cobranding deals with General Mills for selected infant purées and Disney Consumer Products for new toddler products capped a busy 2010 for the Amsterdam, NY-based baby-food company. The products, including new steam-cooked foods called Steamies, are produced in BeechNut’s new $124 million plant. Beech-Nut is seeking silver LEED certification for the facility. Green Giant joins Chiquita in Beech-Nut’s cobranded product portfolio. “The names Chiquita and Green Giant are synonymous with having the highest quality standards and delicious taste,” according to Chief Marketing Officer Evan Eckman, who notes the Chiquita tie-in began almost 20 years ago. The Disney program involves Winnie the Pooh, Tigger and Piglet on new toddler foods for children 12 months and older. Eckman describes the Disney cobranding as a “highly effective communication platform specifi-

` A cobranding program with General Mills’ Green Giant expands tie-ins with other food companies for Beech-Nut purées, while a similar program with Disney adds marketing luster to toddler foods. Source: BeechNut Nutrition Corp.

cally targeted to toddlers’ moms through Disney’s integrated media channels.” The Green Giant relationship means new graphics for some stage 1, 2 and 3 products, though the containers remain the same. “Infant purées are exclusively produced in traditional glass jars,” Eckman emphasizes. Steamies, on the other hand, “are offered in microwave-safe, BPA-free plastic tubs.” They are offered as twin packs of 6-oz. tubs. He describes steam cooking as “a new concept for the US infant foods market. The primary benefit of the steam-cooked technology is retention of taste and textures, which gives our Beech-Nut Steamies a homemade quality, yet the convenience of quick preparation.” ❖

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18

February 2011 | Food Engineering | www.foodengineeringmag.com

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TECHNOLOGY S O U R C E B O O K Focus on Case Cartoning, Loading and Unloading

PACKER/UNPACKER Providing uncasing or case packing for cans, cartons, glass or plastic containers, the compact A-B-C Model 101 Pick & Place packer/unpacker has a PLC-controlled, servo-operated placement head and Intelligent Control electronics with a full-color touch screen panel for revising production parameters, running the self-diagnostic program or executing a changeover. Other features include a SEW Eurodrive motor, quick-change gripper assemblies, synchronized container and case conveyors, solidstate proximity sensors with quick disconnect fittings and photo eyes with background suppression, all in a heavy-gauge steel frame and enclosed by clear guard doors. A-B-C Packaging Machine Corporation; 800-237-5975; www.abcpackaging.com

VFFS BAGGERS USDA and 3A-Sanitation certified (Standard Number 27-06) for both intermittent and continuous models including forming tubes, Triangle X-Series VFFS baggers feature electropolished stainless steel; ground welds; a laser-sealed, die-filled film roller; and sloped control box for product runoff. Control box finishes come in NEMA 4X; the electrical components have an IP65 rating. The baggers are operated by Rockwell Automation ControlLogix. Triangle Package Machinery Co.; 800-621-4170; www.trianglepackage.com

HVAC DRIVES Danfoss VLT HVAC drives come with Smart-Start functionality and Firmware version 3.50 for on-board BACnet communication; an external BACnet module is also available. The variable frequency drives feature a modular design and are configured and tested to customer specifications at the factory. They include integral cascade, fan and compressor controls. Integrated fuses and a disconnect capability are included in each drive enclosure. Danfoss VLT Drives; 800-621-8806; www.danfossdrives.com

www.foodengineeringmag.com | Food Engineering | February 2011

21

TECHNOLOGY S O U R C E B O O K

CASE PICKING SYSTEM The RMT Robotics robotic gantry case picking system can handle discretionary or batch picking operations. The system works in tandem with a conveyor, AS/RS or tow motor that delivers palletized or unitized loads to the area beneath the gantry. From there, the pallets are depalletized for storage and tracked and maintained by the gantry’s built-in inventory management system. The case picker can fit into most existing footprints. RMT Robotics; www.rmtrobotics.com

High performance in a small footprint. The latest addition to the SORTEX E range, the SORTEX E1D offers a high performance sort in a small footprint. It has been designed to bring the benefits of larger sorters to smaller processors while delivering a high quality sorting in the freezing process. A combination of technologies and options allow for processors to tailor the sorter’s inspection system to their specific needs. It’s capable of inspecting product for discolored or misshaped product, subtle blemishes, FM or EVM, or any combination thereof. www.buhlergroup.com Buhler Sortex Inc. 209.983.8400 [email protected]

The small footprint aids installation in areas with limited space Double sided viewing allows an even detection of subtle defects from two sides Advanced PROfile technology enables removal of defective material by viewing the product using shape characteristics Stainless steel open construction design ensures high hygiene standards and easy cleaning The UHMW PE chute feed system delivers frozen product to the optical vision system efficiently Consistent performance without daily calibration ensures a low maintenance requirement High quality color sorting permits both gross and subtle color blemishes to be removed

Safe Food. Clean Food.

22

February 2011 | Food Engineering | www.foodengineeringmag.com

CASE/TRAY PACKING Designed for the food and dairy industries, the Delkor top-load case and tray packing machine has minimized horizontal surfaces, cross members that assist complete drainage and standoff mounting of components for open access. Product contact components can be removed without the use of tools. The servo motors, gear boxes and pneumatics are IP69K rated, and can receive direct contact from a high-pressure hose. Other features include NEMA 4X electrical enclosures with sloped tops, a stainless steel conduit and sanitary ball feet, and 100 percent stainless steel for metal components with FDA-compliant plastic components. Delkor Systems, Inc.; 800-328-5558; www.delkorsystems.com

CELL-POWERED STOCKPICKER The Crown SP 3500 Series fuel cellpowered stockpicker has an on-board display with a fuel cell hydrogen level indicator that allows parameters to be set for a low-fuel warning; a lockout feature prevents lift when the fuel level reaches a predetermined level below the initial low-charge alert. The Crown Access 1 2 3 system control is connected directly to the fuel cell power unit; it manages all truck functions and proactively facilitates 2-way communication with the operator. Crown Equipment Corporation; www.crown.com

TECHNOLOGY S O U R C E B O O K

PALLETIZING ROBOT The KUKA KR 700 PA low-weight palletizing robot has a 4-axis kinematic system and hollow-wrist design with an extra-large opening that allows the energy supply to be routed in the protected interior. The robot has a working speed of 15 cycles/min., a payload of 700kg and a maximum reach of 3,320mm. It can be installed on a pedestal or directly on the floor. KUKA ROBOTER GMBH; www.kuka-robotics.com

LEVEL-LIFT Designed for warehouses with limited loading dock space, the Serco LoadWarrior level-lift has independent-powered lip control, regenerative hydraulics and push-button controls. With a vertical range up to 60 in., the level-lift can load and unload nearly any type of vehicle that pulls into the loading dock. An audible alarm with a flashing yellow strobe light activates when the lift is not fully stored. Safety velocity fuses prevent an uncontrolled descent. With a lifting capacity up to 20,000 lbs., the unit enables dock-to-grade forklift access, and can be interlocked with dock doors, vehicle restraints and other equipment. Serco; 877-933-4834; www.sercocompany.com

WRAPPING SYSTEM The Automated Packaging Systems AirPouch FastWrap protective wrapping system uses high-yield boxes of flat, preformed bubble materials to produce cellular cushioning wrap and air-filled tubes on demand. The cushioning wrap is 12-in. wide with a continuous length and perforations every 10 in. The tubes are available in 14-in. lengths, and are 1 1/4 in. in diameter when inflated. The system features an all-electric design that operates in semi-automatic or manual modes at a speed of 55 ft./min. Automated Packaging Systems; www.airpouch.com

www.foodengineeringmag.com | Food Engineering | February 2011

23

SUPPLY CHAIN INNOVATION STARTS AT PROMAT 2011 ®

From March 21-24, 2011 the material handling and logistics industry will showcase the latest manufacturing, distribution and supply chain solutions at ProMat 2011. Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions. Choose from 80 educational sessions that deliver valuable insights into the latest trends, technologies and innovations. ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you: sStreamline sMaximize

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Learn from the experts at ProMat 2011 ®

The Conference at ProMat 2011 offers unparalleled educational and networking opportunities to manufacturing, distribution and supply chain professionals.

ProMat 2011 On-Floor Educational Seminars

LEVEL LOADER The Southworth PalletPal level loader now has a smaller base that allows users to step closer to the unit’s platform. Heavy-duty springs automatically lower or raise a pallet as weight is added or removed, maintaining the top layer of stacked containers at a convenient height. The turntable ring (or optional turntable platform) at the top of the unit can spin the load so users can stand in the same spot throughout the loading or unloading process. Accommodating loads from 400 to 4,500 lbs. depending on the spring package, the loader requires no power. Southworth Products Corp; 207-878-0700; www.southworthproducts.com or snow; it withstands the constant heat emitted from a 100W incandescent lamp and does not yellow, crack or flake. The globes meet safety regulations in the US, Canada and Mexico including FDA, OSHA, ASME and CFIA. Shat-R-Shield Inc.; www.shatrshield.com

DIGITAL POSITIONERS

GLASS GLOBES Suitable for entrance/exit doors, docking areas, food prep areas, food storage areas and walk-in refrigerators, ShatR-Shield silicone-coated glass globes maintain non-yellowing optical clarity for the life of the products. The safety-coated glass resists thermal shock from contact with hot grease, welding spatters, rain

Spirax Sarco SP400 and SP500 digital positioners consume approximately 1 percent of the air of a traditional electropneumatic positioner. The SP400 model has a simple menu system and can perform an auto-stroke calibration at the press of a single button. The full-featured SP500 positioner includes optional retransmission of valve position; software switches; the ability to use a separate 24 Vdc power supply; and communications protocols as well as diagnostics. Spirax Sarco, Inc.; 803-714-2000

www.foodengineeringmag.com | Food Engineering | February 2011

Choose from more than 80 focused, 45-minute sessions free to all registered Show attendees.

ProMat 2011 Keynotes Co-presented by ProMat 2011 and Automate 2011

Monday, March 21 at 8:45-9:45 am

Fortune Favors the Brave: The Net Gain of Supply Chain Security in a Risk-Based World Tom Ridge, First Secretary of Homeland Security Tuesday, March 22 at 8:45-9:45 am

The Development of Robonaut 2: A Story of Government-Industry Collaboration and Technology Transfer

ProMat 2011 Educational Tracks Tuesday, March 22 at 1:00-4:15 pm

The people side of the supply chain Wednesday, March 23 at 1:00-5:00 pm

Sustainability, the supply chain and their future together The Hub offers informational and educational opportunities for ProMat visitors. Located in the center of the ProMat 2011 show floor, it will feature major attractions that will guide you through your ProMat experience while being a destination in itself.

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TECHNOLOGY S O U R C E B O O K

FORCE MEASURING DEVICE The Lantech LeanWrap CFT-4 containment force measuring device measures the pressure, or containment force, that stretch film exerts on a stretch-wrapped load. Nondestructive, it preserves the wrapping integrity of the stretch film containing the load on which containment force is being measured. Lantech.com; 800-866-0322; www.lantech.com

POCKET FILLER

CHILLED NIP ROLLERS Used with corn, wheat, bran or rice, PFE temperature-controlled chilled nip rollers withstand high pressures and the related heat when opposing rolls are used to crush grain into cereal flakes. Internal water passages are engineered to create flake uniformity by controlling higher temperatures that result from the high-pressure nip process. Outer roll surfaces are ground to within .0002 in. TIR to ensure nip tolerances and consistent flakes. PFE Rolls, Inc.; 978-544-7803; www.pferolls.com

See Food Master, p. 73

The Multi-Fill MPFMP-060 semi-automatic, volumetric pocket filler dispenses clean, accurate portions of difficult-to-fill products including cooked rice, cooked pasta, cut vegetables and fruit, ready-to-eat salads, cereal, surimi, shrimp and shredded meats. The unit’s head has an adjustable volumetric pocket system equipped with a plate product separation device, sharp knife or needle assembly. Discharge is controlled in synchronization with the container flow. A compartmentalized stainless steel enclosure manufactured to NEMA 4X, IP66 standards contains all the pneumatic and electrical components. The filler is rated at speeds up to 50 to 60cpm. Multi-Fill, Inc.; 801-280-1570; www.multi-fill.com

VFD DRIVES Lenze IP65 washdown VFD drives are available in stainless steel or polycarbonate plastic. They come in a package that mounts directly into the motor, eliminating the need for panel space and cables. Lenze Americas; www.lenzeamericas.com

February 2011 | Food Engineering | www.foodengineeringmag.com

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

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TECHNOLOGY S O U R C E B O O K

TRI-SEAL CARTON CLOSER The Kliklok-Woodman Vari-Straight top-load, straight-line closer for tri-seal cartons provides a controlled carton turn without a change in direction; the turning bed features “pop-up” turning bars that capture the cartons and guide them through a 90° turn and into the charlotte closing section. Parameter settings are automatically adjusted based on carton size and speed. Standard features include an Insight color touch screen HMI; and variable-pitch carton transport. Kliklok-Woodman; 770-981-5200; www.klikwoowoodman.com

YARD/DOCK MANAGEMENT SYSTEM The 4SIGHT yard and dock management system integrates a facility with intelligent software to monitor, schedule and communicate trailer movement, load assignment and loading dock status in a single interface. The system combines RFID, GPS and sensor technologies for real-time yard and loading dock visibility. 4Front Engineered Solutions; 866-691-1377; www.4frontes.com

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February 2011 | Food Engineering | www.foodengineeringmag.com

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Complete line of Industrial Lubricants LIQUID FILLING SYSTEM The PallayPack VersaBlock full-featured, automatic monoblock liquid filling system is designed for filling, plugging and pick-andplace capping of any kind of small bottles or vials. Suitable for applications where volumes exceed what can be done manually, the system operates at speeds up to 40 bottles/min. PallayPack; 514-630-1818; www.pallaypack.com

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HEAT EXCHANGERS Combining smooth and cross-corrugated tubes, Krones shell-and-tube heat exchangers offer increased output adjustment flexibility in the handling of a range of viscosity variants from water-viscous to highly viscous products. The exchangers’ volume flow can be regulated from 100 to 30 percent to enable handling large and small containers at the filler without any intermediate discharges. A low-output model handles 3,000 to 10,000 liters/hr.; a medium- and high-output version ranges from 15 and 30 through 60 cubic meters/hr. Krones AG; www.krones.com

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Asset Management Aligning Man & Machine

30

February 2009 | Food Engineering | www.foodengineeringmag.com

A coordinated approach to asset management has value for facilities, equipment and the people responsible for both.

` Kevin T. Higgins, Senior Editor

F

rom the board room to the break room, improving asset performance through better management is on the minds of a lot of food and beverage manufacturing professionals. ASSET MANAGEMENT A sleek new building that sips energy and utilizes natural light is all well and good, but the assets of production pay the bills. Managing the equipment and machinery in the plant is front and center in organizations’ thinking, come good times or bad. When new plant construction bottomed out in 2008 and 2009, relocation of production lines sustained many of the architectural engineering (A/E) firms serving the food industry. “Think of it as a line on rollers,” Walt Staehle half-jokingly says. Much of the relocation work is driven by a focus on boosting supply chain efficiencies, allows the former Kraft production manager and current Siemens automation executive, but the activity underscores a simple truth: It’s easier to walk away from a building than a production line. “Over the last two years, companies have tried to be as efficient as possible in the space they have” to avoid undertaking new construction, observes Michelle Comerford, who heads Austin Consulting’s site selection group. An uptick in greenfield projects began in late 2010 as economic pressures eased and manufacturers maxed out production capacity in existing plants, but decommissioning and relocating of lines accounted for a lopsided share of the Cleveland-based A/E firm’s business in the recent past. By and large, line relocations are driven by one of two factors: a desire to fortify a regional production network to reduce or better manage supply chain costs, oftentimes by lowering labor costs. Line relocations can backfire, however. One food engineer recalls the unfortunate fate of a dry soup manufacturer that used to operate in his facility: After being shipped several hundred miles to another plant, the well-tuned production line never performed the same and eventually was mothballed. The human assets left behind proved to be the key to efficient throughput. “As technology develops, the importance of labor skills increases,” acknowledges Comerford. “There’s something to be said for building up the skill level in a community over

many years.” Recognizing the importance of skilled operators, maintenance technicians and others, food companies often relocate a core group when production shifts to another location, making quality of life a consideration in site selection. The people side of the equation is not limited to highly automated production. “Fresh-cut produce is highly manual and requires specialized people with unique skills,” she notes. “It can take more analysis to move that type of operation.” The acquisition wave that engulfed the food industry at the outset of the 21st century produced a glut of facilities that had to be divested. More than 40 Pillsbury plants transferred to General Mills ownership when that 2001 merger closed, putting thousands of managers, maintenance professionals and others in the accountants’ crosshairs. Reduced overhead is the essence of synergy from a business management perspective. “Synergy means people are going to be fired,” concurs Brian Boyle, senior managing director of McGladrey Capital Markets’ food & beverage group. The Chicago investment banker, who represents both buyers and sellers of food plants, believes the industry is evolving toward a hybrid model in which manufacturers will maintain one megaplant and a network of regional production facilities to ease distribution vulnerabilities as fuel prices increase. Boyle considers many factors when deciding if a plant should be shuttered, and some are beyond the control of the local staff. Nonetheless, the viability of a facility and the jobs it supports is affected by the level of its automation and the quality and working condition of its equipment. Sticking to knitting Obsolete equipment, local tax rates and economic incentives to relocate all can play a role in closing a plant, though Stellar’s Jim Oko cites supply chain considerations as the key to many plant closings. Before becoming director of process engineering at Jacksonville, FL-based Stellar, Oko helped lead a now-shuttered Smithfield pork facility. “The labor efficiency was great, the product was high quality, but it was not on a transportation corridor, and there were logistic inefficiencies,” he recalls. www.foodengineeringmag.com | Food Engineering | February 2011

31

ASSET MANAGEMENT

` Handheld devices like SKF’s Microlog Inspector help boost the integrity of machine condition data and facilitate transfer to asset-management software. Source: SKF Inc.

Rather than dwell on factors beyond their control, production professionals need to focus on what they can control, beginning with the preventive maintenance program. Food safety is entwined with effective PM, and customers are demanding their suppliers upgrade food safety, making food companies receptive to capital spending that enhances it. “Sometimes it’s as simple as bringing a line back to its original specs,” says Oko. Pressure to accelerate throughput beyond design limitations results in lines that strain their operating parameters. “There has to be a handshake with production,” he says. “Maintenance is the most unforgiving job out there.” Unfortunately, the handshake often doesn’t happen, observes reliability engineer Scott Patterson, partially because maintenance funding and PM opportunities are counter cycle: When production is running full tilt, money for PM is plentiful but the opportunity isn’t, and vice versa. Another problem is the tendency of organizations to reward

The Impact of Asset Management Software Metric

Impact

Overall equipment effectiveness

Increased 8%

Maintenance costs

Reduced 9.5%

Asset downtime

Reduced 14%

Source: Aberdeen Group.

32

February 2011 | Food Engineering | www.foodengineeringmag.com

short-sighted behavior. Instead of praising “the white knight who rides to the rescue as calamity looms,” companies should shower rewards on crews who head off disaster by performing diagnostics that flag component wear before major breakdowns occur, he says. Before becoming corporate manager of reliability programs at Pittsburgh-based H.J. Heinz Co., Patterson spent the better part of three decades with Procter & Gamble and as a reliability consultant to industry. Infrared devices for thermal fingerprinting and stethoscopes for lubrication analysis long have been part of his condition-monitoring repertoire. At a pulp mill assignment, the cost of an hour of downtime was calculated at $100,000, so predictive maintenance was a given. But the cost of predictive tools has plummeted and is also within the reach of organizations where downtime costs are more modest. “A good infrared gun that used to go for $40,000 has fallen to $5,000,” Patterson says. Ultrasonic devices also are useful tools in the right hands. Patterson uses them to calculate the thickness of process piping, a useful indicator of the condition of both the pipes and the vessels they are linked to. But the calculations require both data benchmarks and a level of skill operators can’t be expected to have without proper training. “You can pass the baton, but you have to prepare them to be successful or else they will fail,” he warns. Instrument underutilization must be avoided, he cautions. Fellow electrical engineers often take ownership of infrared guns to identify heating and arcing in electrical connection, a useful starting point but not an end-all. He recommends applying the tool to motor and pump connections and other equipment to “learn what good looks like” and identify and replace worn bearings before machine failure occurs. The training imperative Operator-driven reliability is a concept being embraced by a growing number of manufacturing organizations. “People are looking beyond the cost of the asset to the cost of downtime,” reasons Terry Fisher, key account manager of the services division of SKF Inc. in Canandaigua, NY. “Within the total productive maintenance framework, it’s part of autonomous maintenance.” Yet instead of reducing costs, operator-driven reliability can drive it up if inadequate training is provided, Fisher cautions. Over-lubrication is a major factor in bearing wear, yet organizations routinely reassign responsibility without defining the procedures. “Lubrication management has developed into a discipline of its own,” Fisher reflects. Without proper management, autonomous maintenance is destined for failure.

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Worst to First: What Sets Manufacturers Apart Best in Class Implementation of CMMS/EAM

72%

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33%

Maintenance module as part of MES

28%

Source: Aberdeen Group.

Operators also need to be familiar with condition monitoring tools and have an effective way to record the readings. Handheld devices are replacing clipboards, he says, simplifying data collection and paving the way to work-order generation through a computerized maintenance management system (CMMS). Corrupt data undermine attempts to improve asset management. Root cause analysis of machine failures resulted in significant reductions in downtime at Kraft Food’s Chicago bakery, Plant Manager Steve Kunkle related in a presentation at the 2010 Food Automation & Manufacturing Conference, but those improvements would never have happened without the CMMS and data

34

February 2011 | Food Engineering | www.foodengineeringmag.com

cleansing systems he instituted. When he came on board three years ago, data capture was a manual function. With manual systems, workers tend to report numbers that cast themselves in the best possible light, and the distorted Laggards picture of downtime that emerges frustrates efforts to maximize asset utilization. 40% “The key to success is data integrity,” Heinz’s 17% Patterson agrees. “I would rather have no data 8% than bad data and be chasing ghosts.” Renewed interest in lean manufacturing and Six Sigma, along with expanding use of the OEE metric, helps focus attention on asset management, though their effectiveness in improving asset performance is in dispute. “OEE and efficiency numbers are well and good,” allows Jack Roper, controls group design manager at Boise, ID-based POWER Engineers Inc., “but often we find the OEE numbers go up and down, depending on the operations group behind it.” When equipment is ramped up beyond its design limits, consulting engineers will dial them back to improve overall equipment effectiveness. However, retuning operating parameters must be coupled with changes in how production managers, operators and maintenance technicians manage the assets. “We boosted OEE 20 percent at one plant simply by changing human behavior,” says Roper.

A Total Project Solution We see it clearly. Food and Consumer Products Caroline Cooper, 816-822-3831

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ASSET MANAGEMENT Overpromising technology’s abilities Packaging machinery may be the most stressed assets in a plant, according to Kurt Warzynski, manager-process engineering at Stellar. The velocity of change in package sizes and styles requires more changeovers and greater pressure to exceed design speeds. The sourcing of packaging materials can compound the stress. John Gunst, POWER Engineers’ packaging design manager, cites a cartoner that was commissioned and validated with one type of paperboard, then was run with inferior stock. “It killed the operating efficiency of the machine,” he recalls. “The machines don’t change, but the raw materials and the people operating them change all the time.” Lean principles can produce line designs that work against asset utilization, Gunst continues. A glaring example is the minimization or elimination of accumulation points. “You need the right amount of accumulation to keep your bottlenecks from shutting down the line,” he says, yet some lean proponents associate accumulation with muda, or waste, and try to do without surge protection. “Accumulation areas are not just a crutch for a failed system; they have a role,” he insists. “Six Sigma can be taken too far.” CMMS also suffers from misperception. In a study sponsored by CMMS provider AssetPoint, researchers at the Aberdeen Group correlated reductions in maintenance costs and machine downtime and improvements in OEE to implementation of CMMS and other asset-management software (see chart on page 32). Heinz’s Patterson disputes that conclusion, however. Managers who expect quick reductions in maintenance costs are destined for disappointment, he says. “It’s not going to fix your process; it’s just going to track how you’re operating.” CMMS is a very good asset-management tool, he adds, but presenting it as a panacea “is like saying installing Microsoft Word on your computer will let you type 80 words a minute without error.” The Aberdeen research, based on a survey of maintenance professionals, highlights one positive trend in asset management. Downtime reduction, not surprisingly, was the top goal for 57 percent of respondents. Close on its heels at 55 percent was asset-utilization improvement. Alignment of the goals of production with the goals of maintenance bodes well for improvements in asset management. A coordinated approach to assets— mechanical and human—is the most intelligent strategy for improving performance. ❖ For more information: Michelle Comerford, Austin Consulting, 440-544-2682 Brian Boyle, McGladrey Capital Markets LLC, 312-634-3481, [email protected] John Gunst, POWER Engineers Inc., 208-288-6484, [email protected] Jack Roper, POWER Engineers Inc., 208-867-3442, [email protected] Terrance Fisher, SKF Inc., 585-314-2020, [email protected] Jim Oko, Stellar, 904-899-9224, [email protected] Kurt Warzynski, Stellar, 904-260-2900

See Food Master, p. IFC 14

February 2011 | Food Engineering | www.foodengineeringmag.com

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Lubricants

Keep the

gears running Food-grade lubricants have come of age in performance, but the more compelling reason to make the switch from conventional lubricants is to meet regulatory demands. Wayne Labs, Senior Technical Editor

I

f you fail to lubricate processing equipment properly, it may come to a screeching halt before you expected, causing expensive downtime. Plus, if you’re not using foodgrade lubricants, you may well have problems with local, USDA and/or FDA inspectors, who may close down your operation. According to research from Kenji Yano, Yano Consulting, in 2007 roughly 60 percent of processors were not using food-grade lubricants. Beginning in 2000, Yano served five-and-a-half years as the business unit manager of NSF International and was instrumental in setting up the food-grade lubricants program previously under the auspices of the USDA.

Harsh environments Rose Poultry has three locations in Denmark that produce 290,000 poultry products per day. Lubrication is a very important part of

the processor’s preventive maintenance protocol. In the past, the lubrication process was very time-consuming and expensive because the lubricants being used couldn’t always withstand the harsh operating environments, water washout and shock-loading conditions. For example, conveyors and trolley systems must be thoroughly cleaned to ensure food safety. During this process, the poultry processor uses high-pressure washing at 360psi with high-temperature water and chemicals. After one week, most of the food machinery grease and trolley fluid was washed off and rendered ineffective, causing downtime and production inefficiencies. According to Technical Manager Lars Hvass, the spiral freezers also presented problems. Hvass was willing to try Petro-Canada’s Purity FG 00 grease on the freezers before further extending its use throughout the plant. “To be honest, we were skeptical at first because we

The use of H1 foodgrade lubricants keeps equipment running smoothly and also complies with USDA, FDA, ISO and NSF International regulations/ specifications. ExxonMobil Lubricants & Specialties foodgrade oils are used in this beverage filling machine. Source: ExxonMobil Lubricants & Specialties.

www.foodengineeringmag.com | Food Engineering | February 2011

39

Lubricants Rose Poultry made a switch to Petro-Canada food-grade lubricants for all equipment at its three Denmark locations. Source: Petro-Canada.

had already tested several competitor products. We thought Petro-Canada’s lubricant would be just like all the others.” Hvass’s crew was eager find a solution to lubricating the $1 million freezers as stoppages in production were extremely costly. “We tested Purity FG 00 grease in our spiral freezers,” says Hvass. “We were quite surprised. The grease proved to have very good resistance to water washout and breakdown, and it performs exceptionally well, even at -31°F.” Following the successful test in the freezers, Rose Poultry began applying Petro-Canada lubricants in other areas in the plant, including the trolley system where Purity FG Trolley Fluid was used. “Purity FG Trolley Fluid has performed very well,” says Claus Foldager, head of repairs. “It offers excellent wear protection, and we feel that it’ll help to extend trolley life.” Petro-Canada’s REFLO 68A was also tested in the processor’s ammonia compressor system. The ammonia refrigeration compressor fluid is designed to outperform solvent-refined paraffinic and naphthenic refrigerant oils. “We saw a very significant reduction in fluid use,” says Foldager. “Our estimation is that by using REFLO, in conjunction with our systematic preventive maintenance protocol, total fluid consumption has been cut in half.”

The move to H1 lubricants A couple or more decades ago, the USDA created three categories for lubricants used in food and beverage processing plants: • H1—a lubricant that may have incidental contact with a food product, and therefore, if found in a food or beverage product, its concentration must be fewer than 10 ppm (21CFR 178.3570 states 10 ppm maximum for mineral oil). • H2—a lubricant used on equipment and machine parts where there is no possibility of contact with food. • H3—a soluble, edible oil that can be used to provide temporary relief from rusting and can be present in food products. In contrast, 3H is a release agent used on grills, loaf pans, cutters, boning benches, chopping boards or other hard 40

February 2011 | Food Engineering | www.foodengineeringmag.com

surfaces in contact with meat and poultry food products to prevent food from adhering during processing. About 10 years ago, USDA no longer supported testing and compliance, and gave the task to NSF International. NSF maintains these categories of lubricants, but also classifies many other proprietary substances and non-food compounds, including lubricants. NSF still has both 3H and H3 categories. Chemically, H3 mainly is vegetable oil; 3H mainly is white mineral oil. Other standards have been set in place as well, but most countries actually follow the NSF H1 registration requirements for food-grade lubricants, says Colleen Flanagan, Petro-Canada specialty fluids global marketing manager. Governmental registration groups in Canada, Australia and New Zealand handle registration similarly to how USDA once did. Other standardization activity includes DIN EN ISO 22000 in Germany and ISO 21469 and 22000 in Europe. ISO 21469:2006 specifies hygiene requirements for the formulation, manufacture, use and handling of lubricants which, during manufacture and processing, can come into incidental contact (e.g., through heat transfer, load transmission, lubrication or the corrosion protection of machinery) with products and packaging used in the food, food processing, cosmetics, pharmaceutical, tobacco or animal-feeding stuffs industries. The challenge with getting food processors on the H1 bandwagon has been primarily a perception of poor performance compared to H2 lubricants, says Jim Girard, Lubriplate vice president. Thirty years ago, many food processors shied away from using food-grade lubricants which were poor performers. However, in the last 10-20 years, significant advances in additive technology have improved H1 lubricant performance. Additives to H1 lubricants must meet FDA requirements under 21 CFR, Section 178.3570 and other sections referenced therein or classified NSF HX-1 to make the resulting lubricant product H1. While the mix of additives is proprietary to any supplier, their use improves the overall lubricant in many ways. For example, rust inhibitors slow the formation of rust, and this was, according to Flanagan, one of the first obstacles conquered by suppliers. Other additives can be used to enhance the oxidation life of the product, and a relatively new generation of additives prevents the growth of bacteria and fungi in the lubricant. It’s important to remember the purpose of the antimicrobial additives is not to decrease levels of bacteria in food; it is to prevent the growth of microbes in the lubricant

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Twenty years of Innovation continues with Breakthrough in Food Grade Lubricating Fluids Breakthrough formulation results in recognition as Winner of the International Stevie Award for Best New Product or Service of the Year in the manufacturing category. Over the past 20 years, every product in Petro-Canada’s PURITY FG line of food grade lubricants has been formulated to excel under difficult plant conditions, while meeting high safety standards. Petro-Canada has a unique line of white oil based food grade (FG) lubricants including compressor, gear, hydraulic, chain, trolley and heat transfer fluids. Select products include Microl – the first EPA registered antimicrobial preservative for food grade lubricating fluids. Synthetic gear and compressor fluids extend the line for low temperature and specific applications. The high performance of the PURITY FG line of products can be attributed to accumulated formulating experience, using base oils made by the patented hydro-treating (HT) purity process to remove impurities that could hinder performance and additives that are specially selected and uniquely combined to provide the utmost benefit to these highly processed mineral oils. New product opportunities and improvements to the current PURITY FG line are always under review. Improving the oxidation

stability of Petro-Canada’s fluids in order to make them last longer has always been at the forefront of our design considerations. To that effect, PURITY FG compressor fluids use a patented anti-oxidant combination to provide excellent oxidation stability and clean performance. Not only has this been shown in laboratory tests, but also in over 15 years of rotary screw, vane and reciprocating compressor service and vacuum pump applications in food processing plants. Focus on tough food plant conditions The processes and conditions in food plants are tough. Processing equipment must endure the stresses placed on it. Wet and humid conditions from climate or cleaning methods, and start-stop operations provide yet another challenge to lubricant design to ensure sufficient corrosion control, foam dispersion, and water separation. The oxidative stability demands on compressor lubricants become greater as operations grow larger requiring greater volumes of air to operate pneumatics, as process shifts are extended and as

compressor design itself becomes more compact with a smaller footprint. Compressors needing to run over longer time periods may result in hotter discharge temperatures. One factor causing this may be insufficient cooling of the oil. Oil residence times in the sump may be shorter due to system design and/or cooling systems that may prove less efficient due to climate conditions – such as increases in the ambient room temperature or warming of the oil-cooling water. These conditions cause the rate of oil oxidation to increase as the temperature of the oil rises. Further, equipment operating over long time intervals draws in a greater volume of air and concentrates any air borne contaminants– such as fats and oils from food processes or cleaning acids from sanitation procedures. Both circumstances increase the oxidation of the lubricating oil. As the oil oxidizes, the more viscous oil becomes harder to cool, harder to circulate, and can lead to deposits, varnish and eventually a difficult clean out of the equipment when an oil change is made. In compressor fluids, the importance of a fluid’s oxidation stability to ensure smooth operation for lubrication, sealing and cooling is high.

Improving resistance to oxidation The choice of additives and their permitted concentrations in lubricants with incidental food contact are restricted by Food and Drug Administration (FDA), Canadian Food Inspection Agency (CFIA) and various other government bodies. However, loading up a formulation with the maximum quantities of the available additives does not necessarily result in a top-out of oxidation stability and can in fact be detrimental to overall product performance. There are very few opportunities to dramatically improve the performance of already good food grade products while keeping price in measure. That is, until recently. Building upon the unique anti-oxidant chemistry of Purity FG Compressor Fluids, a leap in the level of oxidative resistance is provided with breakthrough technology to yield a significant improvement in performance. Petro-Canada’s new and improved Purity FG Compressor Fluids deliver a dramatic improvement in oxidation stability for robust service in today’s harsh food plant environments.

New and improved compressor fluid Laboratory tests show significant improvement in relative control of oil thickening of the New and Improved Purity FG Compressor Fluid in response to heat and high air flow exposure (Figure 1). Fluid thickening with oxidation IP48/97 (modified) oxidation test, 24 hours 200°C (392°F), 15 L/hr air

the housing in vane compressors, or piston rings and liners in reciprocating units. Improvement in one property can sometimes cause deficiencies in others. Fortunately, tests revealed the same excellent control of deposit build-up as apparent for the original product (Figure 2).

Lab results have shown us oxidative stability mostly comparable to better than the competitive fluids tested (Figures 3, 4).

Deposit Formation -Panel Coker Test, 260°C (500°F), 16 hours, oil flow rate 2.3 mL / hr

Figure 3: RPVOT (ASTM D2272), time to 25.4 O2 psi pressure drop.

Figure 1: The viscosity increase is significantly less for the new formulation.

Rotating Pressure Vessel Oxidation Test (ASTM D2272) confirms this improvement in the resistance to oxidation. Compared to the original formulation, almost double the time is necessary to observe the required 25.4 psi O2 pressure drop in the vessel signalling the end of the test. Isothermal Pressure Differential Scanning Calorimetry, PDSC (200°C) studies further confirm this product enhancement. As an added benefit, an improvement in anti-wear properties is observed for better protection of rotor bearings within rotary screw compressor units, or vane tips as they contract and expand against

Figure 2: Clean test panels are observed for the New and Improved Purity FG Compressor Fluid and the original formulation. In contrast, competitive products tested show deposits on the panels.

As well, good corrosion inhibition is maintained with the new fluid, which is important when running equipment in intermittent service in high humidity conditions. Given the dramatic improvement in oxidation stability of the New and Improved Purity FG Compressor fluid, comparisons of oxidation resistance against other FG products both mineral oil based (MO) and synthetic (Syn) were made.

Figure 4: PDSC (200°C), oxidation induction times (OIT) observed.

Exceptional lab results have provided confidence to test this formulation in a non-food industrial application using a two stage double screw rotary compressor (two compression stages), in a tough industrial operating environment. The test revealed good performance of the fluid.

What can you expect? New and improved Purity FG compressor fluids are the result of breakthrough FG technology that builds on our already excellent properties and provides significantly stronger lubricant performance and durability. A robust fluid, this new and improved fluid with its strong oxidation stability can be used in more severe applications, hotter conditions, more difficult environments, more oxidatively stressful operations than our current product. With significant improvements in oxidation resistance over our already highly oxidatively stable product, expect better performance over the long term. Although the inherent oxidation stability of the lubricant is important, to keep any equipment in top working order good maintenance practices, including the provision for adequate oil-cooling and air filter element replacement, need to be followed. Oil condition monitoring should be part of a preventative maintenance schedule. New and Improved Purity FG Compressor Fluids 32, 46, 68 and 100 fit perfectly in HACCP (Hazard Analysis and Critical Control Point) and GMP (Good Manufacturing Practice) plants. All fluid components comply with FDA regulation 21CFR178.3570 “Lubricants with incidental food contact”. All fluids are H1 registered by NSF.

lubricants.petro-canada.ca

Lubricants US about 18 months ago, and one of the processors talked about how painful it was to have been caught using an H2 lubricant in the hydraulic line above a meat processing Is the H1 grease No miscable with line,” says Flanagan. “Not only was orig. grease? its food recalled, but also it had Yes to shut down, purge the lines and show evidence of all of the remeDoes the Yes diation before it was allowed to go that may stem from contaminated bearing have lube back into operation,” she adds. food. In 2009, JAX Inc. published nipples? “In the average food plant, the a special bulletin to its customers No terms under the line and over the and the public about the use of its line are a generally reasonable, comMicronox antimicrobial. Wash and dry the bearing monsense approach to determining According to JAX Technical when to use food-grade products,” Director Troy F. Paquette, “Microsays Glenn Krasley, Ultrachem sales nox exhibits broad-spectrum antiFill the bearing until & marketing director. “Simply put, microbial activity to protect the new grease comes out of the bearing if it’s over the line (any area that is lubricant against bacteria, yeasts located over or near enough to a and molds. While Micronox proconveyor or other system that provides protection to the lubricant Check outcoming grease visually cesses food), you should certainly from contamination or degradation be using a food-grade lubricant. It’s by foodborne or disease-causing usually the under-the-line instances bacteria, it does not protect users Is that cause problems, because the or others against these bacteria.” grease same in appearance (color worst-case scenario is often overWhile some additives certain& texture) as new grease? looked.” What if one of the hydrauly improve performance, others lic lines ruptures, and the high may hinder it. If processors are pressure of the system produces a looking for high-performance H1 5-ft. spray? Not very likely, but it’s lubricants, some antibacterial or Record analysis data certainly a possibility. Possible sceantifungal agents can potentially narios like this cause many plants to have adverse effects on the peruse food-grade lubes throughout formance of the lubricant, says Mark the lubrication point the entire facility, adds Krasley. Kevin Harrington, global Mobil According to Girard, the use of technical advisor, ExxonMofood-grade lubricants in refrigerabil Lubricants & Specialties. For Bearing is approved for operating with H1 grease tion equipment is growing. “We example, they may have an effect have H1 refrigeration compressor on frictional characteristics of a oil. In the past, this application gear oil or reduce the thermal and oxidative stability of hydraulic oil. He recommends check- usually used standard petroleum products.” There is one simple and important reason to use H1 ing the specifications of the lubricants containing these lubricants throughout the plant, says Girard. If a processor additives very carefully before making a decision. were to use 100 percent H1 lubricants everywhere in the plant, an HACCP plan wouldn’t be required for the lubricaGetting with the program While some applications in a food or beverage plant may tion program and lubricants. Another simple reason to switch everything over to H1 seem far enough removed from food, equipment and its lubrication may touch food in unexpected ways. Flanagan in a plant is to avoid cross-contamination, says Harrington. sees several Petro-Canada users switching air compressor “Given the ongoing requirements for good manufacturing and vacuum systems over to H1 lubrication to avoid any practices, food processors are moving toward H1 lubricants possibility of food contamination from a non-food-grade plant wide. This eliminates the potential for misapplication of an H2 lubricant where H1 is needed.” Harrington points lubricant present in air lines or vacuum lines. Hydraulic lines represent another application ready for a out that when processors make a complete switch of all conversion to H1 fluid. “I did a usage and attitude study in the equipment to H1, contamination with H2 lubricants is one Developing a detailed flowchart for replacing conventional grease with H1 grease in lubricated bearings helps assure consistency and the changing out of grease in each bearing. Source: Schaeffer Manufacturing Co.

44

Replacement of conventional grease by H1 grease in grease-lubricated bearings

February 2011 | Food Engineering | www.foodengineeringmag.com

The following companies supply food-grade lubricants. Aerospace Lubrication www.aerospacelubricants.com

Fuch Lubritech www.fuch.com

Lubrication Engineers, Inc. www.le-inc.com

Bel-Ray Company, Inc. www.belray.com

Haynes Mfgr. Company www.haynesmfg.com

Lubriplate www.lubriplate.com

Chemetall www.chemetallamericas.com

Jax, Inc. www.jax.com

Petro-Canada, Inc. www.lubricants. petro-canada.ca

Clarion www.clarionlubricants.com

Kluber Lubrication www.klubersolutions.com

Please see the 2011 Food Master for a complete list of suppliers:

Schaeffer Manufacturing Co www.schaeafferoil.com

Total Lubricants www.total-us.com

Exxon Mobil Lubricants & Specialties www.mobilindustrial.com

Krylon Products Group www.kpg-industrial.com

Summit Industrial Products www.klsummit.com

Ultrachem, Inc. www.ultracheminc.com

concern they don’t to worry about—whether for regulatory reasons or public/media scrutiny. Once a processor has made the decision to switch to H1 lubricants, some prep stages are necessary. For instance, taking a step at a time, concentrating on one area, application or equipment like Rose Poultry did is a good approach. Then, according to Girard, it’s typically a three-step process to make the change. Most lubricant companies have already put together the proper procedures and the right chemistry to accomplish the changeover. Typically the procedure involves draining the old lubricant, flushing (adding a charge of H1-grade flushing fluid, running the equipment and draining the flushing fluid) and adding a fresh amount of food-grade lubricant. It’s also a good idea to identify and mark all lubrication points in equipment where direct and/or indirect contact occurs between the lubricant and food or where a foodgrade lubricant is to be used in place of a non-food-grade lubricant, says Larry Ludwig, Schaeffer Manufacturing Company chief chemist and technical director. This can be done with tags, labels, etc. Ludwig also recommends a detailed flowchart for each type of equipment, e.g., hydraulic systems, compressors, grease-lubricated bearings, heat transfer systems and gearboxes. Following a flowchart helps to get consistent results, says Ludwig.

Too much, too little, just right Some equipment is easier to gauge than others when determining its lubricant needs. OEM machine manufacturers certainly specify the proper amount of liquid lubricants, but applying the proper amounts of grease can be trickier. When visible/audible problem signs occur, it may indicate over-zealous or under-zealous applications of grease. For example, Ike Trexler, food-grade lubricants marketing manager at Summit Industrial Products, recalls a steam peeler operation where the equipment had manifolds covered with what appeared to be “pigeon droppings.” Each manifold had 12 to 20 Zerk grease fittings leading to shaft bearings. Maintenance people were observed to be coming along in successive visits applying six pumps of grease into each fitting. While the large amount of grease applied

to the fittings connected to 6-in. diameter bearings presented no unsightly mess, the same amount of grease was being applied to 2-in. bearings, which were swimming in grease, and therefore, threw the grease out onto the manifolds, creating a horrible housekeeping problem. Imagine the problem if the grease were H2 and not H1. Trexler’s visit to a major brewery uncovered another unexpected problem—where too little grease was being applied. A large auger that carried grain from the storage side of the plant to the brewhouse needed its bearings replaced every three to six months. A large manifold covered the bearings on the 12-in. shaft. Since the end of this auger was out of any convenient reach, capillary tubes carried grease from a bar of 30 grease fittings over a distance of 200 to 300 ft. to the actual bearing. When asked how much grease was applied and how often, the maintenance manager told Trexler he shot in “three pumps” to each fitting every week. When Trexler made some measurements and calculations, the math showed that with grease applications at this frequency and number, it would take two years for the grease to reach the bearings. Unfortunately, the grease only has a shelf life of a year and a half. Obviously these are not intentional mishaps, says Trexler. The problem is the operations quickly become so massive in size, gearboxes are running in a ceiling or back in a corner, and no one remembers the gearboxes are there until they lock up or break.

Costly mistakes The following anecdote demonstrates the bad information maintenance people often receive. Krasley was touring a bakery facility with its purchasing manager who stated his entire plant operated on food-grade lubricants. While walking the facility, Krasley noticed an open pail of nonfood-grade industrial gear oil. The purchasing manager discovered one of his mechanics had recently completed a repair on a gear drive that had halted production on one of the lines. While the mechanic was picking up a coupling at a local industrial supply house to make the repair, he had also purchased a pail of gear oil. The supply house told him it was food grade, but it wasn’t. ❖ www.foodengineeringmag.com | Food Engineering | February 2011

45

Proliferation of performance-degrading microbes in lubricants can cause serious headaches.

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All PURITY food grade lubricants excel at protecting equipment under severe operating conditions. New PURITY FG2 with MICROL MAX goes a step further by also protecting itself. Revolutionary MICROL effectively inhibits the growth of performance-degrading microbes that can build up in lubricants. Shortening its life. Costing you time and money. And those are headaches you don’t need. The world is changing. Are you? Get your FREE SAMPLE or arrange a TRIAL at lubricants.petro-canada.ca

Petro-Canada is a Suncor Energy business TM

Trademark of Suncor Energy Inc. Used under licence.

PLANT LIGHTING ` Senergy Solutions, a Southern California energy-efficient lighting solutions provider, replaced more than 110 existing 400W metal halide fixtures with Cooper fluorescent 6-lamp T5 high-bay fixtures fitted with integral occupancy sensors. The new lighting and control system reduces energy costs by about 46 percent providing a payback in just 14 months. Source: Cooper Lighting.

The Case for High Benefit Lighting There’s a lot more to new lighting advancements than just saving money. ` Jaan Koel, Contributing Editor

L

amps are like the eyes of a food manufacturing plant, and lamps and eyes have obvious connections. Lamps enable eyes to see and workers to work. Some lamps’ light output drops off faster than others, some shine more brightly, some make better use of energy. According to John Bachner, executive director of the National Lighting Bureau (NLB) in Washington, DC, the time to make lighting improvements in food plants and other manufacturing facilities is now. “Lighting in many industrial facilities is old, obsolete and inefficient, but today because of energy savings, global warming and financial incentives, there are good reasons to upgrade.” The opportunities are plentiful. National, state and local utility programs are offering companies attractive financial incentives to do away with old energy-inefficient fixtures such as T12 fluores-

cents and magnetic ballasts and replace them with newer, more energy-efficient fixtures using T8 and T5 lamps with electronic ballasts. It’s better for the environment, better for the bottom line and better for employees. “The thing to keep in mind when changing lamps and luminaires to ones that save energy is to invest in a holistic design that will provide you with a much bigger bang for your upgrade dollars than just trying to reduce energy costs,” says Bachner. He makes a compelling argument. The other big advantage of “High Benefit Lighting”—a trademarked NLB coinage connoting lighting designed to optimize performance of the activities the lighting is used to illuminate—is the increase in productivity it can bring to an organization. “You have to look at the visual tasks people are performing in the different parts of the business and create a lighting environment that enables each of them to

www.foodengineeringmag.com | Food Engineering | February 2011

47

PLANT LIGHTING causing cumulative trauma disorders (CTDs) such as carpal tunnel syndrome.

` Shat-R-Shield lamps are UL-EPH® (Environmental and Public Health) classified, NSF certified and meet FDA, OSHA, ASME, CFIA (Canada Food Inspection Agency) and Mexico Department of Agriculture and Rural Development regulations. Source: Shat-R-Shield.

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do the best work they can—faster, and with fewer errors,” Bachner notes. “In the food business, take people who have to move blades around, which is fairly common. You better have good lighting that allows those people to see what they’re doing with crystal clarity, no shadows or dark areas, or the consequences could be serious.” Another consideration is spills. High Benefit Lighting will clearly illuminate where and how extensive a spill is. Does High Benefit Lighting pay? You bet. Consider a situation where it costs about $60/year to provide the lighting needed by a worker who earns $30K. Say a lighting company offers to replace lamps and luminaires with newer, more energy-efficient ones and is able to cut that lighting cost down to $30/year. If the lighting reduces that employee’s productivity by 1 percent, the company loses $270/ year. If the lighting helps the employee improve productivity by 1 percent, the company gains $330 over the year. Multiply that by all the employees in the plant, and the result is substantial. Lighting also has an effect on absenteeism and employee morale. “Poor light can result in headaches,” Bachner points out. “If you have glare from smudged windows or poorly placed lights that shine in workers’ eyes, it will strain eye muscles that try to compensate for the problem, or will cause employees to turn their heads, eventually straining neck muscles. In either case, the result is a headache that causes people to go home.” Poor lighting can also cause employees to compensate by adopting awkward body postures, potentially

February 2011 | Food Engineering | www.foodengineeringmag.com

Out with the old, in with the new Food manufacturers and other companies can take solid steps to improve the quality and efficiency of their lighting environments at modest cost. National Light Bureau President Howard Lewis says that on top of current financial incentives from state governments and rebates from local utilities, a comprehensive federal “cash-for-clunker-lighting” program already exists, but not enough lighting decisionmakers are using it. By qualifying for the Commercial Building Tax Deduction (details can be found on the Bureau’s www.nlb.org website), commercial lighting system owners can get a tax benefit of up to $0.60/square foot to offset the cost of a new lighting system installation or retrofit. Using less energy has other important benefits, too, such as lower demand charges. These are based on the rate at which a manufacturing company consumes electricity. Higher consumption at any given time results in higher demand charges to compensate the utility for having to invest in more equipment to meet the customer’s maximum peak requirements. In some cases, these demand charges can equal or even exceed consumption charges. An obvious change any company can make right now is to get rid of T12 systems. Mike Colotti, Osram Sylvania’s vice president for brand management and marketing communications, calls these “true dinosaurs.” Yet, there are an estimated 500 million of T12 lamps still in use. He advises companies not to wait. July 1, 2010 marked an important watershed. On that date, it became illegal to manufacture or import many popular, conventional T12 magnetic replacement ballasts. And the Department of Energy will eliminate more of them as of July 14, 2012. “People need to get those T12 systems out of their buildings while incentives still are available to help offset their costs. Once we reach the point where T12 systems can’t be purchased or maintained—and we’ll be there soon—there’ll be no reason to incentivize owners to replace them. They’ll have no choice.” Colotti estimates owners are spending in the neighborhood of $8 billion a year to operate the 500 million T12 lamps still out there. By switching to T8s, they would save about half—48.8 percent. “And that includes no allowance for a wide range of control-related energy-saving techniques such as occupancy sensing, dimming and daylight harvesting,” he notes.

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PLANT LIGHTING

` Paramount supplied its S8 Series, 2’ x 2’ Surface Mount HID luminaires in a new installation for Normac Foods of Arden, NC. Source: Paramount Industries.

There’s also an important environmental aspect. According to the NLB, T12 lighting accounts for some 3.6 tons of mercury leaching into our environment each year. Going to T8s would cut mercury use by 43 percent and reduce utility carbon emissions by 24 million tons per year. “Some say it’s irresponsible to keep T12 lighting in place, and I would be hard-pressed to disagree,” adds Lewis. Going to smaller-diameter and more efficient T5 lamps is a further option. T5s have been around for about a decade, T8s were introduced in 1981, and T12s way back in 1938. One T5 can replace two T12s. Compared to T8s, a T5 can cut mercury infiltration by 56 percent and CO2 emissions by a further 12 percent. Options aplenty Many companies today provide the latest in energy-efficient, eco-friendly lighting systems along with professional design consultation. One of them is Sitka Enterprises Inc. of East Texas, PA. Brian Roy, Sitka’s president, says much of his business these days is in replacing high-intensity discharge (HID) lighting with more efficient fluorescent systems. “HID is a very typical type of lighting you find in large industrial spaces, such as food plants, and it still has an important role. But as a lighting type, it’s inefficient in terms of watts per unit of output.” Roy also notes that apart from taking more energy, light output performance dropoff over time is more rapid with HID lamps than it

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February 2011 | Food Engineering | www.foodengineeringmag.com

is with fluorescent or LED counterparts, which his company also specializes in. Despite the relatively higher cost of LED lighting, Roy says because of its long lifetime (30,000100,000 hours), it provides the lowest cost per unit of light. Second is fluorescent (20,000- 30,000 hours), and third is HID (10,000-20,000 hours). Because of their higher upfront cost, LEDs are not mainstream—yet—but their time will come as lamp costs continue to decrease. According to Roy, food appeals more to the eye when lit by the natural daylight look of LEDs. This helps at all levels of the food industry— grocery, food service and manufacturing, where they’re a particularly good choice for assembly and inspection areas. “Another benefit is to use them in loading areas, because unlike other lamps, they don’t emit UV radiation, so they don’t attract bugs,” he says. On the fluorescent side, the company’s Ecotube T5 series has a life of 20,000 hours (2.3 years at 24 hours/day, seven days per week). It uses 40 percent less glass and 80 percent less mercury than competing fluorescents, and through the use of the adaptors, it can be installed quickly and easily into existing fixtures, saving time and labor costs. Shat-R-Shield of Salisbury, NC was founded in 1976 and is the original manufacturer of shatterresistant lamps. The company uses several types of clear plastics to safety-coat its lighting products. If a Shat-R-Shield fluorescent lamp accidentally breaks, virtually all hazardous materials like glass fragments, phosphors and mercury will be safely contained inside the skin-tight plastic coating. Risk for employees, customers and equipment is greatly reduced. Shat-R-Shield also manufactures safety-coated incandescent and compact fluorescent lamps along with metal halide and high-pressure sodium HIDs. One of the company’s newest products is its energy-saving 49W T5 HO fluorescent lamp. According to Marketing Manager Bill Hahn, “The T5 HO is a much thinner lamp, but provides a great deal of light per watt. It’s proving popular in retrofitting projects especially in facilities with high- and medium-bay lighting systems.” Holophane, a company located in Granville, OH, has been a key player in the lighting industry for over a century. All its luminaires designed for the food manufacturing market are made of high-temperature acrylic. It’s a robust, transparent material used to properly shield the light source while providing maximum protection for the environment. The enclosures are fully washdown rated

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PLANT LIGHTING

` Bottling equipment is illuminated with a retrofit EcoPower T5 adapter in the original T8 sanitary fixture by Sitka Enterprises. Two 8- ft. 90W lamps were replaced with a single T5 adaptor with two 4-ft. T5 54 watt lamps. Total power savings is 74 watts per fixture. Reusing the existing sanitary fixture minimizes the retrofit costs while maximizing energy savings. Source: Sitka Enterprises.

52

and designed for maximum hygiene. The hightemperature acrylic addresses the glass safety issue, while its highly engineered optical designs create angles for a wide range of dispersion requirements. Tamar Williamson, Holophane’s product manager for indoor markets, says the company’s newest offering is its Petrolux III line. Its hazardous rating makes it ideal for demanding applications such as flour and grain mills. “We introduced Petrolux III last year for multiple lamp sources such as induction and compact fluorescents, and we’re planning to launch additional sources, such as linear fluorescents in the coming months.” Meanwhile, the company’s Vantage line of fluorescent and HID lamps accounts for 95 percent of what it sells to the food industry and is also hazardous rated. Basic American Foods, a 500,000-sq.-ft. dehydrated potato processing plant in Shelley, ID installed a Vantage system featuring 400W metal halide lamps in its granule line and upper preparation area. It replaced a 4-ft. fluorescent system that tended to create a dim, drab environment. “We specified the metal halide lamps because the white light provides better color rendition,” says Basic American Foods Electrical Project Manager Rick Lake. “Operators are constantly looking at the potato products as they transition through the vari-

February 2011 | Food Engineering | www.foodengineeringmag.com

ous stages of processing. The white light helps them better identify any defects.” Steve Guarracino is the Metalux industrial marketing manager for Cooper Lighting, headquartered in Peachtree City, GA. According to Guarracino, Cooper Lighting customers have increasingly been replacing older HID fixtures with multi-lamp T8 and T5 systems, including Cooper’s line of Metalux F-Bay products. “Much of the impetus behind this retrofit activity is the rebate dollars offered by energy providers to lighting system owners—up to $80 per fixture,” he notes. Perhaps most importantly, the energy savings of the multi-lamp systems are substantial. “A typical 400W HID unit consumes 452 watts, depending on the type of ballast, while a T8 producing almost the same amount of light consumes only 222 input watts—less than half that of the HID.” Another advantage of the new fluorescent systems is their capability to dim not only in stages, but also continuously, compared to HID systems with magnetic ballasts, which can’t dim easily. While it’s possible to reduce power to an HID system through a control system, it doesn’t operate instantaneously, and the lamps have to cool before they’re restruck. Fluorescent systems, Cooper’s included, can be fitted with motion sensors so they can automatically turn themselves off when no one’s around. It’s also possible to fit them with daylight harvesting sensors so they adjust their performance to changing amounts of light coming in through the windows, much like the iris of the eye. Utilizing these types of controls can produce even greater energy savings from the lighting system. Cooper’s Metalux VT4 fluorescent fixtures carry a 1500psi rating for applications requiring hose downs, and they work well in both ambient and cold storage environments. Despite the high degree of retrofitting currently being seen, Guarracino says HID is not likely to become obsolete in the near future. “The market has shrunk, but there are still many good reasons to use this type of light source,” he says. “It still serves its purpose as a point source that can add sparkle and brightness to certain environments.” Cooper Lighting has an LED product offering as well, and this is where Guarracino sees real opportunities. “There are some challenges with spreading lumens with LEDs, but this can be addressed optically. In addition, there are still issues with LEDs producing the same amount of lumens as a multilamp fluorescent system in a cost-effective manner. Fluorescents have a very good story, but the gap between them and LEDs is closing.”

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PLANT LIGHTING ` Cooper Lighting replaced existing 400W metal halide fixtures with energyefficient Metalux T5 F-Bay 4-lamp and 6-lamp fixtures for Buena Pak Cold Storage in Buena Park, CA, in cooler 1 & 2, tower and dock, and battery areas of the facility. Source: Cooper Lighting.

Paramount Industries is a family-owned lighting manufacturer employing 40-plus people in Croswell, MI. Paramount has a wide offering of NSF-certified products suitable for food environments, such as the Craft Lite Series, the Techniseal Troffer and HID Series. Since 1947, Paramount has supplied sealed and gasketed lighting products for applications all over the world and is noted for its custom capabilities. Meanwhile, Osram Sylvania (OSI) in Danvers, MA specializes in lamps and ballasts, as well as control systems. In addition, OSI has a subsidiary, Sylvania Lighting Services (SLS) that specializes in providing energy-efficient lighting solutions. One of SLS’s projects was retrofitting Kikkoman Foods’ soy plant in Walworth, WI. Kikkoman wanted to upgrade its lighting system, for both financial and environmental reasons, to provide greater energy efficiency, lower maintenance and better overall quality. SLS replaced Kikkoman’s 400W metal halide and T12 linear fluorescent lamps with 3,000 PENTRON® T5 and ECOLOGIC® T8 linear fluorescent lamps and high-efficiency QUICKTRONIC® electronic fluorescent ballasts. The plant reduced its annual energy load from 2.74 million kWh to 1.51, saving over $97,000 per year. The longer-life lamps saved an additional $10,000 in maintenance, and reduced SO2 and CO2 emissions by WFH

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February 2011 | Food Engineering | www.foodengineeringmag.com

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PLANT LIGHTING ` Holophane installed a Vantage system consisting of 400W metal halide lamps for Basic American Foods, a 500,000-sq.ft. dehydrated potato processing plant in Shelley, ID. Source: Holophane.

8,248 lbs. and 2.3 million lbs., respectively—equivalent to taking 131 cars off the road. Further, Kikkoman received over $67,000 in rebates. “We wanted to do something that would offer us not only financial benefits, but would also allow us to help

defend and protect the environment from needless waste,” said Jere Marheine, electrical engineering supervisor at Kikkoman. “Using Sylvania’s Ecologic line of T5 and T8 linear fluorescent lamps was a fantastic way of turning our vision into a reality.”

Controls are an important part of maximizing the energy savings provided by the many new lamps and ballasts that are now available, according to Sylvania’s Manager of Energy Relations Susan Anderson. “Photo sensors paired with dimming ballasts can turn down the lights near a window or skylight when it’s sunny outside, and back up if it gets cloudy or dark,” she says. “Occupancy sensors turn lights off when people leave, and back on when they return. Occupancy sensors that turn off automatically, but back on manually have proven to save even more energy, because they require someone to make a conscious decision to flick the switch back on.” Other energy-saving options include lighting control panels, plug load controls and whole-building management systems. High Benefit Lighting is becoming more sophisticated. And the more sophisticated it becomes the more energy—and money—lighting system owners will be able to save. Saving money is important, as is minimizing our footprint on the planet. But the fundamental thing is why we have lighting in the first place—to make workers more satisfied and comfortable in their jobs, and their work more safe, accurate and productive. ❖ For more information: John Bachner; National Lighting Bureau; [email protected]; 301-587-9572 Brian Roy; Sitka Enterprises; [email protected]; 610-393-6708 Bill Hahn; Shat-R-Shield; [email protected]; 704-216-2210 Steve Guarracino; Cooper Lighting; [email protected]; 770-486-4105 Tamar Williamson; Holophane; [email protected]; 740-349-4241 Nathan Benavides; Paramount Industries Inc.; [email protected]; Angie Smiley; Paramount Industries Inc.; [email protected]; 810-679-2551 Susan Anderson; Osram Sylvania; [email protected]; 978-750-2864

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February 2011 | Food Engineering | www.foodengineeringmag.com

Calling All Sustainable Plants Food Engineering’s 3rd Annual Sustainable Plant of the Year Award Now is the time to prepare your entry for Food Engineering’s Sustainable Plant of the Year Award. This competition continues Food Engineering’s commitment to recognizing best-in-class manufacturing. The award will be presented to the most outstanding energy-efficient and sustainable food or beverage manufacturing plant project completed in North America during 2010. Submission Deadline is June 1, 2011. th Plant of stainable ing Co. u S 9 0 0 2 rew evada B Sierra N

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Enter your green plant project in Food Engineering’s Sustainable Plant of the Year Award competition today. Contact Joyce Fassl, Editor-in-Chief for entry forms and more information at 610-436-4220, Ext 8519 ([email protected]). Visit www.foodengineeringmag.com and click on Sustainable Plant of the Year call for entries.

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s a supplier of baking mixes, dairy blends, premixes for cheese and tortillas, and other powdered ingredients for the food industry, and a provider of toll blending, Allied Blending & Ingredients, Inc., headquartered in Keokuk, IA, knows the challenges of handling powders, which easily become fugitive airborne dusts. The company had long struggled with two dust collectors at its original California plant, which handled only 10 million pounds of product per year. “We had substantial dust on our equipment, floors and in the air, and our shrink levels were around 1.25 percent,” says Matt Stelzer, Allied Blending’s vice president of operations at the California facility. Stelzer aimed for a much lower shrinkage rate while planning for the company’s new 25 millionpound per year plant, and he knew a sister facility had been pleased with the long-term performance of a dust collection system from United Air Specialists (UAS). After evaluating three dust collection system suppliers for the new California plant, Stelzer and Plant Manager Juan Mora selected a central-system design using the UAS model SFC 32-4 down-flow cartridge collector rated at 15,000 cfm. This unit draws contaminated air in through its top and forces it downward through horizontal cartridge filters. Its high-efficiency filter media traps contaminants, and the air passes through an after-filter before being released back into the plant or outdoors. A reverse pulse of compressed air through the filter cartridges periodically dislodges captured dust, which falls into a receptacle for disposal. With the core unit selected, the central system was then designed so it could handle dust gen-

erated in each of the new plant’s three separate 1200-sq.-ft. production rooms, while complying with FDA requirements. The dairy 3A blending and batch pack rooms required a custom stainless steel duct and CIP design to prevent ingredient cross-contamination. “We use one of the rooms to process whey, nonfat dry milk and yeast, and another for mixing tortilla premixes (batch packs) with salt, sugar and microingredients. So to comply with FDA regulations, 304 and 316 SS duct is used as necessary, and the system is designed to minimize or eliminate areas that can harbor particles,” says Stelzer. To improve air handling efficiency, conserve floor space and address potential explosion venting requirements, the collector was located on a mezzanine above the control room in the center of the plant. From this spot, the collector functions as a central system, ducted to three precisely defined collection points in each processing room. This ensures optimum airflow is pulled from each room’s hoods and carried to the collector. Then clean, filtered air is recirculated back into the airconditioned warehouse to save energy. With its proximity to the ceiling, the mezzanine location also provides contingency for explosion venting through an outside wall. The reduction in product shrinkage from Allied’s old plant to the new one—1.25 to 0.25 percent—is more than modest, and well below the industry average of 1.0 percent. The improvement over the old plant is obvious, as Stelzer explains. “When people familiar with the appearance of a powdered food processing facility visit our plant, they are surprised to learn that we do blending here because it is so clean,” says Stelzer. ❖ For more information: David Gelb; 513-354-8704; [email protected].

www.foodengineeringmag.com | Food Engineering | February 2011

59

DRY PROCESSING TECHNOLOGY

LOAD CELLS Stellar Technology Model CNR960 and CNR96XX high-capacity and high-accuracy tension/compression load cells resist the effects of extraneous bending and off-axis loading. They work in applications requiring long fatigue life and can operate in excess of 100 million fully reversed cycles at full scale. Both units cover ranges from 25,000 to 2,000,000 lbf. The CNR960 provides a 2 mV/V full scale output (nom), and the amplified CNR96XX provides analog or digital output including RS-232, RS485, Modbus and CANbus. Standard operating temperature is from -65° to +250°F, compensated from 70° to 170°F. Stellar Technology, Inc.; 716-250-1900; www.stellartech.com

PARTICULATE MONITOR BinMaster Level Controls’ Model BM-30 LGX particulate monitoring system handles general process and environmental monitoring applications such as continuous emissions monitoring, baghouse filterleak detection and process particulate flow monitoring. It detects many types of particulates including solids such as dusts, powders, granulars and pellets. The system helps processors meet regulatory requirements by detecting leaks before emissions are visible, and prevents the escape of valuable or dangerous powders while providing a cleaner, safer workplace. BinMaster Level Controls; 800-278-4241; www.binmaster.com

CABLE CONVEYORS Developed by Spiroflow, the new line of CABLEflow conveyors is designed for gentle handling applications and installations requiring conveying in multiple planes. They can transfer friable bulk products from single or multiple in-feed points to single or multiple discharge points with little or no damage. Applications include the coffee industry, where they are used to convey coffee beans, and the snack food industry, where they are used to move friable finished products. Spiroflow; 704-291-9595; www.spiroflowsystems.com

BAG DISCHARGING Material Transfer’s Material Master bulk bag discharging system provides dust-tight discharge of non-free flowing materials. A Sure-Seal actuated spout clamping system seals the bag discharge spout for dusttight operation, while a heavy-duty FloMaster breaker-bar bag massaging system ensures product discharge. A Flo-Lock actuated discharge spout closure system halts material flow for partial bag discharging. The discharging system includes a custom operator access platform and fully integrated dust collection. All product contact surfaces consist of 304 stainless steel. Material Transfer; 800-836-7068; www.materialtransfer.com

February 2011 | Food Engineering | www.foodengineeringmag.com

DRY PROCESSING TECHNOLOGY

BAGHOUSE CONTROLLERS FilterSense’s B-PAC series of baghouse performance analyzers and controllers provides a combination of features to help dust collector operators reduce operating costs, improve the process and meet EPA or OSHA compliance simultaneously. The controllers integrate control, sensing and signal analysis to provide time- and money-saving diagnostics, including the ability to detect/locate filter leaks weeks before emissions are visible; the ability to detect/locate failed pulse solenoids that can lead to plugged filters; and the ability to instantly detect/locate ruptured or frozen pulse-jet diaphragms. The controllers also provide intelligent filter cleaning, which extends filter life and lowers emissions while reducing compressed air usage. FilterSense; 978-927-4304; www.filtersense.com

LUMP BREAKER Munson Machinery’s Model RDC1515-SS sanitary lump breaker features side removal bed screens for rapid, thorough washdown. The all-stainless, low-profile unit reduces agglomerates and friable materials being discharged from process equipment, storage vessels and shipping containers. Material entering the 15-in. (381mm) square inlet is reduced in size by dual rotors with three-point, singlepiece, stainless steel breaking heads rotating with minimum clearance inside a curved, perforated bed screen. Munson Machinery Company, Inc; 800-944-6644; www.munsonmachinery.com

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February 2011 | Food Engineering | www.foodengineeringmag.com

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The Practical Membrane Technology Short Course, a two-day short course, organized jointly ntly tl with ith Filtration Filt ti and Membrane World and Dairy Foodss Magazine Magazine. This course will be broken up into 2 days with the first day focusing on fundamentals of membrane technology and the second day focusing on new membrane technologies and applications.

WHO ATTENDS? Technicians, Chemists, Scientists, Processors, Plant Engineers, Product Formulators, Equipment Manufacturers, Sales & Marketing Specialists and anyone else interested in learning about new methods to eliminate process bottleneck, enhance efficiency, and increase profitability in the food processing industry.

WHY ATTEND? • Learn from industry experts who will cover fundamentals of membranes, process design, cleaning, economics and new applications • Participate in case studies dealing with process design, optimization and practical problems in membrane applications and fouling • Discover new energy saving and efficient membrane technologies from manufacturers • Explore new uses of microfiltration, ultrafiltration, nanofiltration and reverse osmosis applications • Study how to develop a cleaning program for new membrane applications ...and much more! re!

our Get Y rship so Spon day! To TOM IMBORDINO Publisher/Midwest Regional Sales P: (773) 755-8990 [email protected]

R EGI STR ATIO N FE ES FULL 2-Day CONFERENCE REGISTRATION Early Bird – $795 (before March 31, 2010) Standard – $895 (after March 31, 2010) SINGLE DAY REGISTRATION Early Bird – $495 (before March 31, 2010 Standard – $595 (after March 31, 2010) DAY 3 TOURS $75

Learn More at www.membranecourse.com Visit our website or contact your sales rep V to learn more about sponsoring this event.

DR. SEFA KOSEOGLU Filtration and Membrane World LLC P: (979) 764-8360 [email protected]

WAYNE WIGGINS, JR. Western Regional Sales P: (415) 387-7784 [email protected]

AMY VODRASKA Eastern Regional Sales P: (973) 970-9000 [email protected]

CATHERINE WYNN Inside Sales P: (847) 405-4010 [email protected]

DRY PROCESSING TECHNOLOGY

MIXING/ DISPERSING SYSTEM

LOW-PROFILE SIFTER Kason’s Model K40-1FT-SS Flo-Thru sanitary sifter reduces height requirements while increasing screening capacity. The low-profile configuration employs two unbalanced-weight gyratory motors mounted on opposing exterior sidewalls of the unit, instead of one motor positioned beneath the screening chamber. On-size particles pass rapidly through the 40-in. (1016mm) diameter screen in a vertical, straight-through discharge path. Intended to scalp oversize particles through a screen mesh as fine as 38 microns (400 mesh) from dry bulk materials or solids-laden slurries, the screener is available in diameters from 18 to 84 in. (457 to 2,134mm). Kason Corporation; 973-467-8140; www.kason.com

MATERIAL MASTER ™

Charles Ross & Son Company’s new mixing and dispersion system combines a Ross high-shear mixer and a specially designed PowerMix to manufacture fine dispersions. The two mixers are mounted on a common base and connected with piping to allow continuous circulation of materials until the desired dispersion is achieved. A built-in control panel permits fine control of all agitator speeds, amperage and run times. Software is available to ensure the desired results are achieved repeatedly, batch after batch. The PowerMix includes two hi-viscosity planetary stirrers, two highspeed dispersers and a scraper to wipe the sides of the vessel. The variable speed (11-110rpm) planetary blades are driven by a 1-1/2hp motor; the variable speed (900-9000rpm) high-speed dispersers are driven by a 3hp motor. Charles Ross & Son; 800-243-7677; www.mixers.com

BULK BAG MATERIAL CONDITIONER

NEW patent-pending design delivers superior performance ‰

Safely and ef¿ciently returns your hardened materials to a free-Àowing state

‰

Most compact footprint in the industry

‰

Exclusive pivoting conditioning arms outperform traditional compression plates

‰

Factory testing of your speci¿c materials prior to equipment investment

‰

Stand alone unit or integrated with our bulk bag discharging system

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Custom engineered for your application requirements

Visit www.materialtransfer.com or call: 800.836.7068

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February 2011 | Food Engineering | www.foodengineeringmag.com

We have a seat at the Exchange Ches Jackson President Monogram Foods Jeff Johnson Vice President Operations Monogram Foods

SEPTEMBER 11-14, 2011 THE LODGES AT DEER VALLEY PARK CITY, UTAH

“The productivity during PTX has saved us months of time and the partnerships created have contributed to our bottom line.” Contact Becky Simon-Burton to reserve your seat [email protected] - 952-736-9361

DRY PROCESSING TECHNOLOGY

YES, YOU CAN:

Sift, scalp, de-lump and dewater, then remove internals through hinged end cover, with Quick-Clean Centrifugal Screeners

Sift, scalp oversize contaminants and contain dust when dumping manually with Bag Dump Screening Stations

AGITATOR-HOPPER Sift, scalp at high rates in low-headroom areas with Low-Profile, High-Capacity Vibratory Screeners

Sift, scalp at low cost on short notice with fast-ship Single Deck Screeners

USA: 1 973 467 8140

[email protected]

www.kason.com

66

X-0821

CAN: 1 514 667 6777 UK: +44 (0)1782 597540 AUS: +61 (0)3 5977 1181

February 2011 | Food Engineering | www.foodengineeringmag.com

Designed specifically for handling bulk materials known to generate combustible dust, National Bulk Equipment’s agitator hopper is constructed with explosion protection and control features, including an explosion venting system (calculated on a Kst value of 170 and Pmax of 9.5psi) to direct and release overpressure to prepared areas. Hopper construction includes reinforced walls and cover, and is rated for 4.5psi internal pressure. The 100-cu.-ft. capacity hopper provides thorough material conditioning using dual, counter-rotating agitator shafts, each with a proprietary blade design that directs material toward the center discharge. National Bulk Equipment, Inc; 616-399-2220; www.nbe-inc.com

DRY PROCESSING TECHNOLOGY

BAG DUMP STATION Hapman’s FL series bag dump station efficiently minimizes dust when introducing bagged ingredients into a process by employing a self-contained filtration system with a collection efficiency of 99.9 percent down to 0.5-micron particle sizes. A reversepulse cleaning system with tool-less access to the filter cartridge makes it easy to quickly wipe down the system and change out filters for batching and general maintenance. For additional dust containment and process efficiency, a bag compactor can be paired with any of the supplier’s bag dump stations. Hapman; 800-427-6260; www.hapman.com

FEX04074Mart_2.indd 1

3/8/07 3:09:13 PM

ENGINEERING THAT WORKS. Triple/S Dynamics’ sales engineering works with the customer in developing specifications for the equipment. This often includes testing in the company’s application laboratory, site visits to study the installation, and preliminary design engineering services to best match the equipment application.

BENEFITS OF THE SANITARY STAINLESS STEEL SCREENING CONVEYOR Ŷ Ŷ Ŷ Ŷ Ŷ Ŷ Ŷ

Quick Removable Screens Fast Cleaning Better Sanitation Reduced Noise Levels System Flexibility Floor Mounted Ceiling Suspended

www.sssdynamics.com

866-684-6576

www.foodengineeringmag.com | Food Engineering | February 2011

67

DRY PROCESSING TECHNOLOGY

ity of the receivers has been enhanced to increase the receiving volume of bulk materials. The design meets cGMP sanitary requirements, with all components constructed of stainless steel. The receivers also feature a sanitary design, reverse jet polyester cartridge filters, tri-clover quick-release fittings and band clamps for quick disassembly. The P-Series is available in three models including: the P10 (10 liter capacity) conveys up to 600 kg/h (1320 lb./hr.); the P30 (30 liter capacity) conveys up to 1800 kg/h (3960 lb./hr.); and the P100 (100 liter capacity) conveys up to 4000 kg/h (8800 lb./hr.). K-Tron America; 856-256-3265; www.ktron.com

Experience.

When it comes to putting pasta into prepared foods – no one has more experience than 
".

DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934 defranciscimachine.com [email protected] 321-952-6600

DUMPER KEEPS DUST DOWN Flexicon’s Tip-Tite high-lift box/container dumper provides dust-free operation while discharging into vessels from 6 to 10 ft. (183 to 305cm) above the plant floor. The dumper allows boxes and other containers to be loaded at floor level, sealed against a discharge hood, elevated and tipped, mating the hood outlet to a gasketed inlet port fitted to any receiving vessel. The unit accommodates Gaylords and other boxes from 36 to 48 in. (915mm to 1,220mm) on a side and 39 to 44 in. (990mm to 1,117mm) overall height. The container platform is raised by a single hydraulic cylinder, creating a dust-tight seal between the top edge of the container and the underside of the discharge hood. A second hydraulic cylinder raises the platform-hood assembly vertically before tipping it to a motion-dampened stop at 60° beyond horizontal, causing the vertically oriented hood outlet to mate with the receiving vessel’s horizontally oriented inlet port. Flexicon Corporation; 888-353-9426; www.flexicon.com

RECEIVERS EASE POWDER HANDLING Redesigned K-Tron Premier P-Series central receivers handle powders, poorflowing powders and fragile materials, providing a custom solution for difficult conveying applications. The modular-

CONTINUOUS COLLECTION SYSTEM Nilfisk’s Longopac system works like an endless collection bag that can be dispensed as needed to any length and volume for the company’s CFM S3 industrial vacuum cleaner. Once filled, the plastic bag can be cut, sealed, disposed and immediately restored for a new use. The collection system is suited to a variety of food applications that generate a lot of dust. The system is available with a 26-gallon stainless steel collection container. Nilfisk; 800-645-3475; www.foodprocessingvacuum.com

See Food Master, p. 49 February 2011 | Food Engineering | www.foodengineeringmag.com

TWIN SCREW FEEDER Schenck AccuRate’s volumetric or gravimetric MECHATRON twin screw feeder features all stainless steel construction with an internal agitator for handling cohesive materials. Interlocking portions of the unit’s helix act as a self-cleaning device and prevent excessive buildups around the helix and discharge areas. Operators can remove the feed hopper and helixes for cleaning, servicing or reconfiguring without removal of the internal agitator from the feeder, saving overall system operation time. Accuracies of ±1/4 percent are achievable when using the supplier’s dual strain gauge load cells in gravimetric configurations. Feed rates in both volumetric and gravimetric models range from .07 to 50 cu.ft. per hour. Schenck AccuRate; 800-558-0184; www.accuratefeeders.com

BAG DUMP STATION Va c - U - M a x ’ s Model 104121 bag dump stations are available with an integral dust collector and special flanged discharge outlet to mate with the user’s existing equipment. The bag dump stations feature a unitized body fabricated with the fewest possible welds and a strong frame constructed with square tubing. The stations are available in 304 or 316 SS, and vibrators are an option. Units meeting USDA requirements are also available. Vac-U-Max; 800-822-8629; www.vac-u-max.com

www.foodengineeringmag.com | Food Engineering | February 2011

69

’s

The Ritz-Carlton

APRIL 3-6, 2011 The Ritz-Carlton, Palm Beach, Florida

2011 PROGRAM • Register @ FoodAutomationConference.com and SAVE $300 FOOD AUTOMATION AND MANUFACTURING CONFERENCE AND EXPO is the industry’s only event presenting real-world solutions on automation, processing and packaging innovation, sustainability and food safety topics for Operations, Engineering and Manufacturing executives.

W Sunday, April 3

the need for better management of both human and equipment assets.

12:30 p.m.

Golf Tournament 3:00 – 5:30 p.m.

Registration 7:00 – 8:30 p.m.

Welcome Reception

W Monday, April 4 7:00 a.m. – 3:30 p.m.

Registration 7:00 – 8:00 a.m.

Continental Breakfast 8:00 – 8:10 a.m.

Welcome Patrick Young, Publisher, Food Engineering 8:10 – 8:30 a.m.

Opening Remarks: The State of Food Manufacturing Joyce Fassl, Editor in Chief, Food Engineering

Theme for Day One: Continuous Improvement in Challenging Times 8:30 – 9:15 a.m.

Keynote Address: The Road to Manufacturing Innovation

GOLD SPONSORS

Keynote Speaker: Carlos del Sol, Vice President, Global Engineering Systems, Campbell Soup Company All food and beverage processors are searching for innovative practices to gain a competitive edge. In a constantly changing and challenging manufacturing environment, the speaker will address globalization, operational efficiency and

9:15 – 10:00 a.m.

Reaping Rewards with Reliability Improvement Speaker: Peter Hock, Senior Director of Continuous Improvement, ConAgra Foods Overall equipment effectiveness is a widely-applied method to track productivity. But many managers struggle to understand why OEE gains don’t always drive cost savings. The answer becomes clear when we look at the types of events or levers that drive OEE. Managers will quickly recognize that each lever has its own cost profile. With that knowledge, managers may use cost-benefit analysis to focus on OEE initiatives that will drive the greatest financial impact. 10:30 – 11:45 a.m.

and economic justifications for undertaking plant automation capital investments. Join your peers as they create best practices and recommendations for gaining approval on critical plant improvement projects. 12:00 – 1:30

Expo and Lunch 12:00 – 4:00 p.m.

Expo 1:00 – 4:00 p.m.

Solutions Theater 2:00 to 2:30 p.m.

Refreshment Break Stations 5:00 – 6:00 p.m.

Expo Reception 6:00 – 8:00 p.m.

Project Economics: Selling Plant Automation Improvements Moderator: Christopher Miller, Food Industry Consultant and Founder & CEO, Innovation Focus In this interactive session, audience members will collaborate on project cost analysis

Palm Beach Dinner

W Tuesday, April 5 7:30 a.m. – 1:00 p.m.

Registration

SOLUTIONS THEATER SCHEDULE Monday, April 4th 1:00-1:30 p.m.  Retrotech 2:00-2:30 p.m.  Schneider Electric 3:00-4:00 p.m.  SeeIT Solutions/SAP 4:00-4:30 p.m.  Burns & McDonnell

Tuesday, April 5th Track A 8:00 - 8:30  CDC Software 8:30 - 9:00  Atlas Copco 9:00-9:30 a.m.  Siemens Industry, Inc. 9:30-10:00 a.m.  Solarsoft Business Systems

Track B 8:30 - 9:00  Clarion 9:00-9:30 a.m.  Adept Technology 9:30 - 10:00  Beckhoff

Visit www.foodautomationconference.com for the latest Solutions Theater and program updates.

Register today and

SAVE $300!

7:30 – 8:30 a.m.

Solutions Theater 10:30 – 12:00 noon

Educational Tracks on State-of-the-Art Methodologies

Zelusky

Jeffries

The enthusiasm for sustainable manufactur-

Adapting to the New World of Food Safety at the Plant Level

8:00 – 10:00 a.m.

Palczewski

w w w.FoodAutomationConference.com

1:45 to 2:30 p.m

Expo and Breakfast

Monkeiwicz

Developed and Produced by:

Kovach

Posada

SESSION A: PACKAGING TECHNOLOGY 10:30 a.m. Implementing a Successful Robotics System Speaker: Peter Monkeiwicz, VP of Operations, Kayem Foods Inc. 11:00 a.m. Case Study: New Packaging Materials Implementation Project Speaker: Bob Palczewski, Engineering Director, Celebration Foods 11:30 a.m. Changing the World Through Lean Six Sigma Speaker: Tina Kovach, Continuous Improvement Manager, Dawn Foods

Speaker: Greg Flickinger, Director of Manufacturing, Snyder’s-Lance, Inc. Driven by a rapid enhancement in scientific capability, the paradigm in many Consumer Packaged Goods facilities has rapidly changed from a visibly clean standard to a microbiologically clean expectation. Ingredients once deemed low risk have quickly become higher risk. Processes and procedures considered effective are now viewed as inadequate. This combined with imminent governance and regulation has created an environment where production plants must change not only processes and procedures, but culture overnight. This session will focus on the process of transforming culture to keep pace with the new reality of food safety.

ing practices can sometimes be squashed by energy initiatives with high up-front costs. This speaker will focus on overlooked opportunities with solid paybacks. 9:00 – 9:45 a.m.

Maximizing Your Corporate Social Responsibility Plan Speakers: Ed Delate, Vice President Global Engineering and Corporate Social Responsibility, Keystone Foods and Dennis Treacy, Senior Vice President of Corporate Affairs and Chief Sustainability Officer, Smithfield Foods Worker involvement and buy-in are critical for an effective corporate sustainability program. These speakers will discuss how educating both employees and suppliers,

3:00 to 3:45 p.m.

Sanitary Design of Equipment: What You Should Know Speaker: Al Koch, Director of Engineering, Global Biscuit, Kraft Foods Nabisco Division Recalls and food contamination can be avoided by implementing state-of-the-art sanitary design standards. This session will present practical and pertinent information from food manufacturing leading user groups such as AMI (American Meat Institute) and BEMA (Baking Equipment Manufacturers and Allieds).

and encouraging changes in their behavior, can result in tremendous potential for reducing resource consumption. 10:15 – 11:00 a.m.

Quantifying Your Energy Inputs Speaker: Peter Truitt, President, Truitt Brothers This session will help participants

SESSION B: PROCESSING TECHNOLOGY 10:30 a.m. Metal Detection/X-Ray Speaker: Paul Zelusky, Manager of Quality Assurance, The Hershey Company 11:00 a.m. Combustible Dust and Plant Safety Speaker: Kevin Jeffries, Corporate Safety Systems Manager, Imperial Sugar 11:30 a.m. Clean-in-Place Speaker: Alex Posada, Project Engineer, Campbell Soup

3:45 to 4:30 p.m.

to effectively manage your energy usage

Plant of the Year Award

and costs as well as your greenhouse gas

12:00 to 1:00 p.m.

4:30 to 6:00 p.m.

Networking Luncheon

Plant of the Year Celebration Cocktail Reception

Speaker: Peter Takacs, Manager, Quality

Dinner: On Your Own

Spoetzl BreweryBreweries and other

Theme: Best Practices in Operations, Safety and Quality

Join us as we honor the 2011 Food Engineering Plant of the Year award winner. Each year, only one food or beverage plant in North America earns this award.

understand how much energy is used to make products at any given time and more importantly, the cost of those energy inputs for a finite period. Learn how

emissions. 11:00 – 11:45 a.m.

Maximizing Sustainability Benefits While Managing Wastewater Challenges Assurance, food and beverage processors frequently face wastewater challenges that threaten

1:00 to 1:45 p.m

Global Manufacturing Innovation From the Merger of Giants

SILVER SPONSORS

Speaker: Diane Wolf, Global Vice President, Safety and Environmental Sustainability, Kraft Foods Integrating Cadbury, one of the world’s biggest confectionery companies, with Kraft Foods, one of the world’s largest food companies, is an immense challenge. This presentation will explain how Kraft Foods is creating a “best of the best” approach by aggregating and implementing best practices from operations in 160 countries to achieve manufacturing excellence around the globe.

not only their regulatory requirements

W Wednesday, April 6

but also their relationships with local

Theme: Sustainable Plant and Process Practices

municipalities or water utilities. At the same time, identifying cost-friendly projects that help meet sustainability goals

7:00 – 8:00 a.m.

remains a focus. This session will describe

Continental Breakfast

one brewery’s wastewater challenges, the rationale behind the environmentallypositive path chosen, and the output and

8:15 – 9:00 a.m.

Building and Maintaining Success in Energy Conservation Speaker: Daniel Fonner, Senior Manager, Global Utilities, Heinz North America

expected on an ongoing basis. 12:00 noon

Conference Adjourns

QUESTIONS? Contact Marge Whalen, Senior Event Manager at 847-405-4071 or [email protected]

SPECIAL ADVERTISING SECTION

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

Severe Environment Lighting

Maintain Spray Nozzle Life

Rig-A-Lite offers a complete line of innovative and energy efficient hazardous location, high-pressure hose down and corrosion resistant lighting solutions for food processing environments, where rugged lighting products are required.

For your free copy, call or email: 713-378-7831 [email protected] Rig-A-Lite 8500 Hansen Road Houston, TX 77070 www.rigalite.com Bimba Manufacturing

BETE Fog Nozzle, Inc. 50 Greenfield Street Greenfield, MA 01301 T (413)772-2166 • F (413)772-6729 www.bete.com • [email protected] Reserve your FREE 2011/12 Cole-Parmer® General Catalog

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.

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.

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

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

Cleaning Vats and Bins Has Never Been Easier

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Improved reliability, proper performance, and maximum wear life of a spray nozzle often start with correct material selection. Let BETE Engineers help you select the most compatible material for your processing nozzles. Our expertise will help you stand up to harsh environments.

Vibratory Selection Guide

Douglas Machines offers a full line of Vat and Bin Washers that will save you time, labor, energy and chemicals. Our recently introduced Model DVBW1000-C cleans one bin or two vats at a time at the push of a button! For literature, pricing and specifications call 800-331-6870.

Eriez’ complete vibratory product line presented in an easy-to-use manner, with a broad overview to help select the proper equipment. Eriez’ innovations provide for a large array of feeding and conveying equipment options.

Douglas Machines Corp. 2101 Calumet Street, Clearwater, FL 33765 Phone: 727-461-3477 or 800-331-6870 Email: [email protected] Web: www.dougmac.com

Visit www.eriez.com or call 1-888-300-3743.

February 2011 | Food Engineering | www.foodengineeringmag.com

SPECIAL ADVERTISING SECTION

LI TE R AT U R E & P R O D U CT R E V I E W Gravity Metal Detector

DRUM DUMP FEEDER All-new TIP-TITE™ Drum Dump Feeder hydraulically raises a drum platform, creating a dusttight seal between the drum rim and the underside of a discharge cone. A second hydraulic cylinder tips the platform-hood assembly and drum. A cantilevered flexible screw conveyor then elevates and/or volumetrically feeds the material into downstream equipment, dust-free at controlled rates. Finished to sanitary or industrial standards. Flexicon Corporation 1-888-353-9426 [email protected] • www.flexicon.com

FOSS FoodScan™ Sets the Standard You need rapid analysis. FOSS has solutions for the lab and on the line. Measure fat, protein, moisture, collagen and other parameters affecting cost and quality with the most versatile, reliable, accurate systems available. FoodScan is the only AOACapproved near infrared (NIR) instrument. And until December 17 you get FoodScan Pro/Fat-only for a reduced price. Contact FOSS today!

The Gravity system is normally utilized for Bulk product (such as flour, rice, & cereals). The product under test is gravity fed through a pipe system and travels through the detector’s aperture. Gravity systems typically include an automatic reject system to remove contaminated product from the flow. Applications include: Flour, Grains, Cereals, Powders, Snacks, Rice, Corn, Sugar, Chemicals, Nuts, and Frozen Vegetables. We welcome you to visit us at these upcoming shows: - West Pack, Booth # 5130 - Candy Show (PMCA), Booth # 105 - Wisconsin Cheese Industry Conference, Booth # 19 - AMI, Booth # 2373

Fortress Technology Inc. Tel: 1-888-220-8737 or 416-754-2898 [email protected] • www.fortresstechnology.com

New Fristam PD Pump Fristam’s new FKL A positive displacement pump features a clean, rounded exterior; split-style gearbox for easy access to bearings and shafts; and customizable port-to-port dimensions for easy drop-in replacement of other PD pumps. The FKL A is built for no-disassembly-required “True CIP”. Its balanced rotors and large-diameter shafts make it durable and reliable.

FOSS www.foss.us [email protected] Toll free: 800-547-6275

Fristam Pumps USA www.fristam.com/fkl

Hapman Releases Powder and Bulk Solids Material Density Guide I.J. White Spiral Systems Hapman has released a new bulk material density guide consisting of powder and bulk solids. A comprehensive online reference tool to help customers determine the correct specifications in designing a system. It is readily available on every product page It offers easy access to hundreds of material densities and is especially user-friendly since it includes a compound search option that quickly identifies the specific material customers are looking for.

For more information, go to www.hapman.com. Print copies in standard format can be requested by calling 1-800-427-6260.

MAGNETS FOR PRODUCT PURIFICATION AND EQUIPMENT PROTECTION IMI’s new TRAMP METAL catalog features industry-leading Magnetic Separation Equipment for the removal or recovery of metals from a wide variety of dry or liquid processing applications. Recent additions include the Pneumatic Line Housing- the world’s most efficient and effective magnet for purifying in closed systems; the Continuous Clean Housing, designed for on-the-fly cleaning of contaminants while still protecting the process flow; and the RotoDrawer™ unit for poor flowing gravityfed applications. Industrial Magnetics, Inc. Boyne City, MI USA p: 231.582.3100 • w:magnetics.com • e: [email protected]

This new 6 page brochure from IJ White describes the technical services being offered for spiral cooling and freezing systems. These services include system relocation, training programs on preventative maintenance, sanitation procedures and system trouble shooting. IJ White Systems 20 Executive Blvd Farmingdale, NY 11735 Phone: 631-293-2211 Fax: 631-293-3788 E-Mail: [email protected] www.ijwhite.com

SANITARY, LOW PROFILE SIFTER New “Flo-Thru” Sanitary Sifter employs two gyratory motors on opposing sidewalls, instead of one motor beneath the chamber, reducing height significantly. On-size particles pass rapidly through the screen in a vertical straight-through discharge path at higher rates than with circular screeners having a centrally mounted gyratory motor and horizontal discharge paths. Oversize material exits through a side discharge spout. Kason Corporation +1-973-467-8140 [email protected] • www.kason.com www.foodengineeringmag.com | Food Engineering | February 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 Martin Brothers, Inc. Heat Exchangers

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.

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.

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

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

Mokon’s Iceman Full Range This full range heating/chilling system combines a Mokon water temperature control system with an Iceman portable chiller into one compact, selfsupporting system. This system is ideal for processing applications requiring multiple zone control or processes requiring both heating and chilling. Custom options include: NEMA 4/4x, wash down capabilities, and stainless steel cabinetry.

Newark Wire Cloth 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.

For more information, contact Mokon at 716-876-9951 or visit www.mokon.com. 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

Reid Supply Company

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

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

SEALMASTER ENGINEERED INFLATABLES Reid Supply Company is a Michigan-based, global industrial supply company stocking standard as well as hard-to-find products for general consumers and manufacturers including Manufacturing; CAD and Engineering; Transportation Construction; Food Processing; Packaging; Oil, Gas and Alternative Energy; Government; Aerospace; and Medical.

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.

Reid Supply Company 2265 Black Creek Rd • Muskegon, MI 49444 Phone: 800.253.0421 • Phone: 231.777.3951 Fax: 800.438.1145 ReidSupply.com

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www.foodengineeringmag.com | Food Engineering | February 2011

81

AD INDEX

Untitled-1 1 COMPANY

Americold Logistics Ashworth

PHONE NUMBER

PAGE

www.americoldrealty.com

5

COMPANY JAX

8/27/10 PHONE NUMBER

800-782-8850

18

800-682-4594

15

Kason Corporation

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Atlas Copco

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Lubriplate Lubricants Co.

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AZZ Rig-A-Lite

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Martin Brothers

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Material Transfer & Storage

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Midwestern Industries Inc.

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800-965-6065

10

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Perfex

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Bete Fog Nozzle, Inc.

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MPE Group

Bimba

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Omega Engineering Inc.

Breddo Likwifier

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IBC

Buhler Sortex Inc.

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Petro-Canada Lubricants

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Powder Solutions

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Reid Supply Company

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Eriez Magnetics

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Flexicon Coporation

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Cablevey Conveyors

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www.seweurodrive.com

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Specialty Equipment

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Summit Industrial Products

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Gre-Con

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Triple S Dynamics, Inc.

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Hapman

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Ultrachem, Inc.

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Harpak

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Urschel Laboratories, Inc.

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1

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Vac-U-Max

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Volkman, Inc.

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29

www.inpro-seal.com

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Industrial Magnetics, Inc. Inline Industries, Inc. Inpro/Seal

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.

82

10:23 AM PAGE

February 2011 | Food Engineering | www.foodengineeringmag.com

ENGINEERING R&D Kevin T. Higgins, Senior Editor

Membranes and milk

`

Separation technology helps researchers isolate components in milk, but understanding precisely what those components do remains an active area for research. Scientific understanding of the elements of food and how they interact with the human body remains in its infancy, and the more complex the food, the more research that is needed. This is especially true with milk, one of the most complex foods. Concerns over fat content and its role in cardiovascular disease put milk producers on the defensive in recent decades, though new studies suggest milk consumption may actually reduce the risk. Besides identifying milk’s many components and their effects on health, cost-effective ways are needed to isolate and deliver them in the proper concentrations. Researchers are straddling the worlds of medicine and commercial food production as they apply filtration and membrane technology. Multidisciplinary collaboration is needed, and a number of organizations have been formed to foster it. Among them is the Institute of Nutraceuticals and Functional Foods (INAF), which was founded in 1999 on the campus of Laval University in Quebec, Canada. The American Dairy Science Association recognized the contributions of INAF’s director, Yves Pouliot, when it presented him with

` Yves Pouliot, director, Institut des Nutraceutiques et des Aliments Fonctionnels, Université Laval, Quebec. Source: Institute of Nutraceuticals and Functional Foods (INAF).

the 2010 International Dairy Foods Association Research Award in dairy foods processing. Dr. Pouliot received his undergraduate and doctorate degrees in food science and technology from Laval University. He cofounded Advitech, a Quebec firm specializing in the development of bioactives from milk. After Advitech became a publicly traded company, Pouliot rejoined the Laval faculty and applied his expertise in membrane separation, first as scientific director and then director of INAF, which includes a network of 10 university and other research institutions. His work in the development of bioactives from milk has resulted in collaborations with major protein-based ingredients manufacturers, such as Davisco, Glanbia and Fonterra. Among Pouliot’s seven patents is a process for the enzymatic treatment of whey proteins to produce antihypertensive peptides.

FE: How prominent was membrane technology when you began your research activities in the 1980s? Pouliot: Adding value to whey was the focus then.

The ingredient business was booming. In the prior decade, we saw more reliable membranes being commercialized, with new materials of construction for improved chemical resistance and sanitary designs. At the time, ultrafilitration (UF) technology provided an industrial tool to process whey and add value to its protein components because of UF’s flux (separation efficiency), selectivity and ability to process large quantities. Once we discovered that UF could be used to eliminate lactose and concentrate protein, a chain reaction occurred: Each time we learned one thing, three or five other avenues of research emerged.

FE: In what areas has membrane separation had the greatest impact? Pouliot: In dairy processing, there are three main

areas: as an alternative to centrifugation, evaporation and other processes; as a way to resolve separation issues such as defatting of whey and fat globule fractionation; and as a tool for new products, such as UF cheeses and whey-based beverages. It’s estimated that more than 75 percent of total area of UF and reverseosmosis membranes installed worldwide are used in whey processing. Milk processing alone accounts for 25 percent of the installed base of UF membranes. FE: Many of your discoveries have been applied to life sciences, but food applications seem to lag. Why is that? Pouliot: We have developed some processes that

www.foodengineeringmag.com | Food Engineering | February 2011

83

ENGINEERING R&D ` The line between food and pharmaceuticals is blurring as researchers investigate the interactions between food, nutrition and human health. Source: Institute of Nutraceuticals and Functional Foods.

are ready to jump to commercial dairy use, but the economies aren’t there yet. The food industry needs affordable technology, which is why processes like chromatography have not been applied. For example, we have used chromatography and electrofiltration to isolate high-value lactoferrin. It commands a price of about $500 a pound, but you need to process 13,000 liters of milk (about 3,430 gallons) to harvest a pound of lactoferrin, and it can’t be done cost-effectively by a dairy. FE: Significant advances in membrane technology occurred in the 1980s and 1990s. Has innovation continued? Pouliot: Not so much. Because of merg-

ers and consolidation, there are really only three companies left in membrane technology. In the absence of new technical tools, we have focused on ways to improve efficiencies and maintain flux. Membrane technologies have not been fully exploited in the dairy industry for the development of bioactives and other milk-based ingredients. Unless you have a very revolutionary new product, it’s difficult for mainstream processors to justify the cost. Even when the product is revolutionary, companies often have to develop the market for it, and that takes time and money. FE: Fluid milk achieves a richer mouthfeel after ultrafiltration. Why is that? Pouliot: Very few researchers have

studied the organoleptic effects of UF 84

because of the complexity of the milk itself. Identification of which components are at play in affecting mouthfeel is a big question. Some of my current work involves fractionation of buttermilk and whey buttermilk. Buttermilk is sometimes added to chocolate milk to improve the flavor, but that’s not a very high-value use. The use of UF to preconcentrate milk for cheese production has increased the availability of whey buttermilk. It contains a milk fat globule membrane that is rich in proteins and phosphilipids and could be valuable in both functional and nutraceutical applications. Fractions rich in these components could be important in improving both food systems and human health. FE: Two of your US patents relate to the use of whey proteins for treatment of hypertension. What prompted the work? Pouliot: Hypertension is estimated to

be a factor in almost three in 10 adult deaths in industrialized countries. An ingredient company approached us to develop effective processes and dosages of hydrolysates from whey protein isolates to reduce heart rates and blood pressure associated with hypertension. Because public funding supports INAF’s work, our mission is to promote better living by expanding knowledge of human nutrition and health. Accomplishing that mission becomes more attractive when dairy ingredients are involved, since 70 percent of Cana-

February 2011 | Food Engineering | www.foodengineeringmag.com

da’s milk is produced in Quebec and Ontario provinces. So when an industrial partner asks us to help address ailments like psoriasis that pose significant health risks, we are able to help. One patent involves the combination of transforming growth factor with dairyderived proteins. The first step was to conduct a couple of pilot trials to establish the proper dosage factor so a pill that delivered an effective dosage could be made. Buttermilk has some very interesting minor components, including some that seem to lower cholesterol. We’re beginning clinical trials this year with high-cholesterol patients to determine effectiveness and proper dosing. FE: Is there much coordination with similar research conducted in the United States? Pouliot: Individuals certainly col-

laborate. Some of my research on buttermilk has been in conjunction with researchers at California Polytechnic in San Luis Obispo. But institutionally, cross-border collaboration is difficult. The individual researcher is focused on his own work. To collaborate, you have to have open minds. It’s not natural or easy to collaborate, but it can be very effective. FE: You have written about the shelf-life extensions made possible by the uniform transmembrane pressure concept from Tetra-Laval and the introduction of industrialscale microfiltration. Are equipment advances ever a focus of INAF collaborations? Pouliot: There is collaboration, but

commercial secrets are a problem. Every time we begin a project, we get stuck on confidentiality issues. Most of the cooperation involves donations of fillers and other equipment to our pilot plant. ❖

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