Food Engineering January 2011

SPECIAL REPORT: PROCESSORS MOVE TO AUTOMATED DATA COLLECTION FOR QC, HACCP January 2011 | www.foodengineeringmag.com T...

Author: Joyce Fassl

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SPECIAL REPORT: PROCESSORS MOVE TO AUTOMATED DATA COLLECTION FOR QC, HACCP January 2011 |

www.foodengineeringmag.com

THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT

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Access Granted

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JAN UARY 2011

www.foodengineeringmag.com

FEATURES COVER STORY

70

Plant Security: Access Granted The potential for malicious behavior in food manufacturing is an ongoing issue, but security concerns also extend to workers and the controls that run today’s plants.

83

Automated Data Collection Tablet PCs, PDAs and even Kindles are replacing clipboards for manufacturers migrating to automated data collection systems for quality control, including HACCP checkpoints.

95

Tender Birds, Tough Poultry Processing Challenges Despite improvements in technology, poultry processors are taking it on the chin with environmental issues and the rising costs of water and energy.

113 Plant Profile: Kleinpeter Farms Dairy Flexible new ice cream facility mixes up homegrown success.

123 Tech Update: Non-thermal processing As consumers desire fresher tasting food, the challenge for processors is to produce bacteria-free products while maintaining flavor, color and texture.

DEPARTMENTS 8

74

Editor’s Note

12

Calendar of Events

15

Manufacturing News Defining the Food Safety Modernization Act

21

Food Packaging Space: sustainability’s final frontier

28

Food Safety There’s a new sheriff in town

98

31

Technology Sourcebook Focus on PACK EXPO Products

138 Field Reports Connect with FE on Facebook www.facebook.com/FoodEngineering

Follow FE on Twitter http://twitter.com/FoodEng

Join FE’s Group on LinkedIn Food Engineering Magazine

Produce supplier achieves efficiency with MES/ weighing system.

147 Show Portraits & Show Previews 169 Classified Advertising 175 Engineering R&D Interview with 2010 Packaging Hall of Fame inductee Bob Dodrill. www.foodengineeringmag.com | Food Engineering | January 2011

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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], 630-694-4351 Wayne Labs Senior Technical Editor [email protected], 215-345-4548 Richard Stier, Morgan Smith, Jaan Koel, Allen Merritt, Mark Huffman, Olin Thompson Contributing Editors ART & PRODUCTION Karla Fierimonte Art Director [email protected] Suzanne Fairman Advertising Production Manager [email protected], 253-946-6854 MARKETING Marge Whalen Food Automation & Manufacturing Conference Manager [email protected], 630-694-4347 Amy Kozyra Marketing and Event Coordinator [email protected], 847-405-4071 Chris Frost ProcessTechnologyXchange [email protected], 952-224-4390 Jill L. DeVries Corporate Reprint Manager [email protected], 248-244-1726 LIST RENTAL Rob Liska List Manager (postal) 800-223-2194 x726, [email protected] Shawn Kingston Account Manager (email) 800-409-4443 x828, [email protected] AUDIENCE DEVELOPMENT Amy Schuler Group Audience Development Manager Megan Neel Corporate Fulfillment Manager Carolyn M. Alexander Audience Audit Coordinator FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT: Tel. 847-763-9534 or Fax 847-763-9538 or e-mail [email protected]

FOOD ENGINEERING Volume 83, Issue 1 (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].

BNP Media Helps People Succeed in Business with Superior Information See Food Master, p. 73

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www.foodengineeringmag.com NORTH AMERICA SALES Patrick Young Publisher & District Sales Manager 600 Willowbrook Lane, Suite 610 West Chester, PA 19382 [email protected] Tel: 610-436-4220, ext. 8520; Fax: 610-436-6277 Mid-Atlantic Territory: CT, Eastern PA, NJ, NYC and LI, VA, MD, DE, Washington DC

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Carolyn Dress Inside and Online Sales Manager Tel: 847-405-4046; [email protected] Suzanne Sarkesian Classified Sales Manager Tel: 248-786-1692; [email protected] Peter Havens Senior Group Publisher Michael Leonard Group Publisher INTERNATIONAL SALES Gabriele Fahlbusch IMP InterMedia Partners GmbH Tel: 49 (0)202-27169-15; Fax: 49 (0) 20227169 20 [email protected] Germany, Switzerland and Austria

To learn more about our replacement parts programs, including inventory management and specially developed service kits, call Klaus Brinkrode at 201-784-4335 or email him at [email protected].

Fabio Potesta Mediapoint & Communications SRL Tel: 39-010-5704948; Fax: 39-010-5530088 [email protected] Italy CORPORATE DIRECTORS Publishing Timothy A. Fausch

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Finance Lisa L. Paulus Creative Michael T. Powell Directories Nikki Smith 1400T

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Production Vincent M. Miconi

Human Resources Marlene J. Witthoft Conferences & Events Emily Patten Clear Seas Research Beth A. Surowiec

EDITOR’S NOTE

Seeking innovation? I want to let you in on a little secret

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

f you find yourself wondering how to transform your manufacturing operations to achieve higher levels of profitability as we enter 2011, I’ve got some good news and some bad news. The bad news is, most likely, you’ll be asked to stretch the budget once again and obtain even more efficiency from both your equipment and people. The good news is there are many resources that can provide assistance, although sifting through the numerous supplier solutions, trade shows, publications, webinars and events can sometimes be overwhelming. But I want to let you in on a little secret. Did you know more than 95 percent of the surveyed Food Automation & Manufacturing Conference & Expo attendees each year rate the event as excellent? The reason I’m telling you this is twofold. First, true innovation is within your reach. Second, one of the best ways to achieve it is by networking with food industry colleagues in an educational atmosphere.

In addition to top-notch food and beverage executive speakers from Campbell Soup, Kraft, ConAgra, Heinz and more who’ll discuss innovation, continuous improvement and sustainability, we’ve expanded the 2011 program to also delve into technical topics such as CIP, combustible dust and plant safety, robotics and metal detection/X-ray equipment, all presented by food and beverage processors. If you’re not one of the Food Engineering readers who attend the event each year, I urge to consider joining us at the Palm Beach Ritz-Carlton on April 3-6, 2011. Turn to pages 110-111 in this issue or visit www.foodautomationconference.com to view the full schedule and to register for the early bird discount. We’re offering an expanded number of sessions and topics in 2011, outstanding speakers, fantastic networking opportunities and reasonable hotel rates in a luxury atmosphere. This 2011 combo is one you shouldn’t miss. I look forward to welcoming you to this special industry event in April. ❖

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

8

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

January 2011 | Food Engineering | www.foodengineeringmag.com

Alex Peele Director of Project Engineering Interstate Brands Corp.

Dan Sileo Vice President, Manufacturing Sunny Delight Beverages

Hendrik Eyselee Senior Program Manager, Processing Kraft Foods

David Haase Vice President of Operations WILD Flavors

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Thank You for Making PACK EXPO International 2010 a Huge Success!

Don’t Miss

The Next Great PACK EXPO “In this industry, you have to go to PACK EXPO. We got the best leads that we’ve ever gotten at a show. We made twenty sales off the ﬂoor.”

September 26-28, 2011 Las Vegas, Nevada USA

Laurie Mackie, President, Fox Packaging Services, PACK EXPO International 2010 Exhibitor

Mark your calendars today! Learn more at www.packexpo.com.

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September 26-28, 2011 Las Vegas, Nevada USA

Another Successful Show for PACK EXPO International 2010 PACK EXPO International 2010 welcomed 44,000 visitors • The 10 ﬁnalists in the 5th Annual PACK EXPO Selects™ to McCormick Place this year on October 31 – November 3. competition. The show spanned more than 1 million net square feet and offered solutions from 1,835 exhibiting companies. • Project 2020: The Consumer Experience, sponsored by DuPont, which explored packaging developments and PACK EXPO International received visitors from over 125 concepts likely to occur over the next 10 years. countries, a 15 percent increase in international attendance over the 2008 show. That included No other show will have a record 46 international “PACK EXPO International 2010 was the industry support that delegations, representing 34 PACK EXPO has now countries—a 155 percent deﬁnitely a success,” say Charles D. Yuska, jump in delegations, and a 26 and will have in the future. president & CEO of PACK EXPO producer percent increase in international Important allied associations, PMMI. “Trafﬁc was consistently strong, and delegates. like National Confectioners the exhibitors I spoke with were very pleased Association (NCA), Institute with the quality of leads they received. In 2010, PACK EXPO of Packaging Professional I think it’s also signiﬁcant that exhibitors International launched the (IoPP), Reusable Packaging were queued up to reserve booth space for show’s expansion to include Association (RPA), Grocery processing solutions alongside PACK EXPO Las Vegas 2011. It demonstrates Manufacturers Association packaging. “We mirror the the value exhibitors were receiving from this (GMA) and as many as 20 industries we serve, and more associations sponsored year’s event, and what they know to expect consumer packaged goods events and pavilions. from PACK EXPO Las Vegas 2011.” companies (CPGs) see production as a single, continuous function,” says “By partnering with organizations that matter to our attendees, PMMI president & CEO Chuck Yuska. Roughly 20 percent we created new pavilions and educational opportunities that of exhibitors—including the 179 exhibiting companies in the delivered value on and off the show ﬂoor,” Yuska says. “Our Processing Zone—showcased their processing–related solutions. strong contingent of partners brought an extra level of value Innovation took center stage at PACK EXPO this year as new elements were added to focus on the ideas and concepts driving packaging and package design. New elements included: • The Showcase of Packaging Innovations,® sponsored by The Dow Chemical Company, displayed award-winning packages from 19 organizations, a record for the program.

to attendees in general, and their members and constituents in particular.” PACK EXPO returns to Las Vegas next fall, September 26 – 28 at the Las Vegas Convention Center. Yuska says, “Expect the same level of innovation—if not more!”

Learn more at PACKEXPO.com, or contact PMMI’s Show Department at 703-243-8555.

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CALEN DAR JANUARY 2011 17-19: 2011 Northwest Food Manufacturing & Packaging Expo & Conference; Oregon Convention Center, Portland, OR; Northwest Food Processors Association; 503-3272200; www.nwfpamembers.org 19-21: 25th International Forum on Process Analytical Chemistry; Baltimore Marriott Waterfront, Baltimore, MD; IFPAC; 847-548-1800; www.ifpacpat.org/food

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23-26: Dairy Forum 2011; Doral Golf Resort & Spa, Miami, FL; International Dairy Foods Association; 202-737-4332; www.idfa.org 26-28: International Poultry Exhibition; Georgia World Congress Center, Atlanta, GA; US Poultry & Egg Association; 770-493-9401; www.internationalpoultryexposition.org

FEBRUARY 2011 7-10: ARC World Industry Forum; Renaissance Orlando at SeaWorld; Orlando, FL; 781-471-1000; www.arcweb.com 19-23: 2011 AFFI Frozen Food Convention; Hyatt Regency Embarcadero, San Francisco, CA; American Frozen Foods Institute; 703-821-0770; www.affi.com 27-March 2: 31st Annual RFA Conference; Naples, FL; 770-452-0660; www.refrigeratedfoods.org

MARCH 2011 20-23: SNAXPO 2011; JW Marriott Grand Lakes; Orlando, FL; Snack Food Association; 800-628-1334; www.snaxpo.com 26-30: American Bakers Association Convention; JW Marriott San Antonio Hill Country; San Antonio, TX; 202-789-0300; www.americanbakers.org

APRIL 2011 3-6: Food Automation & Manufacturing Conference and Expo; Ritz-Carlton, Palm Beach, Palm Beach, FL; Food Engineering, www.foodautomationconference.com

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13-16: AMI International Meat, Poultry and Seafood Industry Convention and Exposition; McCormick Place, Chicago, IL; 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

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

www.klsummit.com

P.O. Box 131359 Tyler, Texas 75713

For more information, see pages 110-111.

800.749.5823 January 2011 | Food Engineering | www.foodengineeringmag.com

Terlotherm® 12-18: Interpack 2011; Düsseldorf, Germany; Interpack Processes and Packaging; www.interpack.com

Scraped Surface Heat Exchanger The Smart Alternative

17: Continuous Flow Thermal Processing of Multiphase/Particulate Foods; NC State University, Raleigh, NC; 919-515-2957; www.ncsu.edu/project/ foodengineer/short-course

JUNE 2011 11-15: IFT11 Annual Meeting & Food Expo; New Orleans, LA; Institute of Food Technologists; 312-604-0238; www.ift.org 21-23: PACKEX 2011; Toronto Congress Centre, Toronto, ON; Canon Communications; 289-971-0534; www.canontradeshows.com

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

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

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

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APRIL 2012 15-18: 2012 American Bakers Association Convention; Fairmont Scottsdale, Scottsdale, AZ; 202-789-0300; www.americanbakers.org

JUNE 2012 25-29: IFT12 Annual Meeting & Food Expo; Las Vegas, NV; Institute of Food Technologists; 312-604-0238; www.ift.org

SEPTEMBER 2012 23-26: InterMopro, InterCool and InterMeat 2012; Düsseldorf, Germany; Messe Düsseldorf North America; 312-781-5180; www.mdna.com

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SAN TARY

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`NEWS PLANT OPENINGS & EXPANSIONS Bushman

Family

Farms

opened a 42,000-sq.-ft. poultry processing plant in Charles City, IA. Once owned by All-States Quality Foods, the plant has been expanded to include an enclosed drivethrough truck unloading and cleaning section. The facility currently has 90 employees and processes 100,000 chickens per week.

Diamond Foods will double the size of its kettle potato chip production facility in Beloit, WI. Construction is expected to be complete in 2012.

Mikawaya USA, creator of Mochi ice cream, opened the doors to a new 103,000-sq.-ft. plant near downtown Los Angeles. Mikawaya specializes in the production of Japanese pastries and desserts.

Mars Petcare US Inc. is planning to consolidate its regional distribution operations in a 1.3 millionsq.-ft. building in West Jefferson, OH. The $52.7 million project is expected to create 40 full-time jobs.

Hershey plans to add 335,000 sq. ft. to its Eastern Distribution Center warehouse near Hershey, PA. The company is closing an aging West Shore distribution facility as it shifts activity to the new location, where $250-300 million will be invested. Cone Distributing Inc., located in Ocala, FL, will build a new $16 million distribution center. Construction is expected to begin by July and be finished in a year.

Defining the Food Safety Modernization Act S. 510: An act to amend the Federal Food, Drug, and Cosmetic Act with respect to the safety of the food supply

TITLE I—IMPROVING CAPACITY TO PREVENT FOOD SAFETY PROBLEMS TITLE II—IMPROVING CAPACITY TO DETECT AND RESPOND TO FOOD SAFETY PROBLEMS TITLE III—IMPROVING THE SAFETY OF IMPORTED FOOD TITLE IV—MISCELLANEOUS PROVISIONS

T

he FDA Food Safety Modernization Act (S. 510) passed the Senate with several amendments designed to balance coverage fairly among large, small and mediumsized farms/producers/processors. While there has been much argument about what the 241-page document covers, here are a few specifics. First, the act doesn’t change the powers of the Federal Meat Inspection Act, Poultry Products Inspection Act or Egg Products Inspection Act; however, it makes no reference to USDA/FSISmonitored products, e.g., beef, poultry and pork. Second, since the act addresses the responsibility of exporting countries to provide safe food to the US, the US must be allowed to have its own inspectors visit foreign sites when necessary. In addition, there are provisions for electronic data sharing, training of foreign governments and producers, multilateral

acceptance of lab methods, testing and detection techniques and “recommendations on whether and how to harmonize with requirements under the Codex Alimentarius.” Third, there is supposed to be increased monitoring of processors under FDA jurisdiction, and electronic recordkeeping will almost be an absolute necessity for fast response times to recalls. According to Jack Payne, CDC Software vice president of enterprise software, S. 510 will expand the powers of FDA to conduct more frequent inspections and set testing requirements of food facilities, standardize mandatory recalls and the closing of facilities, provide access to additional records and more comprehensive data collection, provide assistance to state and local governments in handling food emergencies and establish new regulations, and ensure imported foods meet the same standards. “The Tester-Hagen amendment is not the only provision in the final bill that

www.foodengineeringmag.com | Food Engineering | January 2011

15

MANUFACTURING

`NEWS would help small businesses and farmers,” says Jaydee Hanson, senior policy analyst at the Center for Food Safety. “There are provisions from Senators Sanders and Stabenow that would help small processors. Altogether, their amendments introduced some 60 places in the bill where it

16

directs the FDA to help small farmers and processors or exclude them from most of the regulations of the bill.” With the small staff the FDA has had over the last 10 years or more, frequent inspections haven’t been conducted at plants like Peanut Corporation of America.

January 2011 | Food Engineering | www.foodengineeringmag.com

Hanson isn’t convinced the bill improves the situation. “The bill does not just protect big Agribusiness, but it does give them a laughable inspection schedule. In the first five years, the most hazardous facilities only have to be inspected once, and then every three years after that,” he states According to Hanson, the same section on getting foreign governments to do a better job makes clear the bill doesn’t apply to dietary supplements and their ingredients regulated by the Dietary Supplement and Education Act of 1994. The problem is, according to Hanson, that this bill maintains the status quo of some 12 agencies monitoring American’s food products. Hanson thinks a Cabinet-level food safety agency is the best long-term solution. Concerning electronic recordkeeping, biannual registration for regulated entities is required within five years, says Hanson. Results of food safety tests may be sent to FDA electronically. Processors that have been certified as GFSI-compliant will have a head start with the new bill, says Payne. “These facilities have already been inspected by certified auditors and should pass FDA inspections with flying colors.” However, for those that are not participating in GFSI certification nor required to participate in HACCP, the new regulations and inspections will present new challenges, he adds. “It will be the many small regional and local food facilities that will be challenged by the recordkeeping and track and trace regulations that will become law,” says Payne. “Initially, many of these facilities will not have the resources and expertise to develop HACCP-based food safety plans, nor will they have resources for records maintenance. In order to comply, they will have to increase prices to cover the additional costs of compliance or risk fines for non-compliance.” Whether small and medium-sized processors must implement track and trace will depend on how FDA interprets the act and its amendments, says Hanson. FDA is specifically charged with examining “the feasibility of such technologies for different sectors of the food industry, including small business,” according to S. 510.

REGULATORY WATCH Vitamin D recommendation may be increased

barriers and create a more favorable trading relationship between the two nations. Essentially negotiated during the Bush Administration, final agreement was held up af ter the Obama Administration requested some changes.

Rep. Kevin Brady (R-TX), in an early December speech to the US Chamber of Commerce, said he believed the house would pass the Korea agreement, as well as trade pacts with Columbia and Panama, in the first six months of the 112th Congress, which begins in January.

The Institute of Medicine (IOM) has submitted recommendations to the US government on the roles of vitamin D and calcium in human health. USDA and the Department of Health and Human Services are currently revising the dietary guidelines for Americans. IOM recommended 700 to 1300 milligrams daily of calcium consumption. For vitamin D, the IOM recommended daily vitamin D intake of 600 international units (IU) for those between the ages of 1-70 years and 800 IU for those older than 70 years. That’s a significant increase from previous recommendations of 200-600 IU. The government’s dietary guidelines committee will consider the IOM recommendations but is not required to incorporate them into the final Dietary Guidelines due for release in the next few weeks.

New trade agreement with South Korea Food producers and processors welcomed the announcement by the US government that it had reached agreement w ith South Korea on a long-awaited trade agreement. Grocery Manufacturers Association President and CEO Pamela G. Bailey said she hoped Congress would quickly approve the deal. “Exports of food and other household products manufactured in the US have exceeded imports for three straight years, supporting jobs in thousands of communities across the country,” Bailey says. “Expanded access to new export markets for American businesses is vital to the future growth of the US economy.” As with other trade agreements, the South Korea agreement would remove www.foodengineeringmag.com | Food Engineering | January 2011

17

MANUFACTURING

`NEWS INDUSTRY & PEOPLE PepsiCo agreed to acquire 66 percent of Wimm-Bill-Dann Foods, a major

Del Monte Foods Company and an

Russian branded food and beverage company, for $3.8 billion, pending the required government approvals.

Kohlberg Kravis Roberts & Co. L.P., Vestar Capital Partners and Centerview Partners have signed a

investor group led by funds affiliated with

definitive agreement under which they will acquire Del Monte for $19.00 per share in cash.

PepsiCo appointed Timothy P. Cost to the newly created position of executive vice president, global corporate affairs.

NEW

BRYANT

MACKAY

David Mackay retired from his post as president and CEO of Kellogg Co., and Chief Operating Officer John A. Bryant has assumed the role of CEO.

The Hershey Co. named J.P. Bilbrey to the newly created role of chief operating officer. Bilbrey was the president of Hershey North America. General Mills will purchase Mountain High Yogurt from Dean Foods in a sale that is expected to be complete in early 2011.

YoCream International, Inc. entered into a definitive merger agreement with Danone under which a subsidiary of Danone will merge with YoCream. Mark A. Duffy joined ConAgra Foods, Inc. as vice president and general manager of Spicetec Flavors & Seasonings. The Grocery Manufacturers Association (GMA) appointed John Hewitt as director, state affairs.

Sara Lee signed an agreement to purchase Cafe Damasco, a Brazilian coffee company, for $60 million.

18

January 2011 | Food Engineering | www.foodengineeringmag.com

ABB will acquire Baldor Electric Company based on an agreed transaction where ABB will pay $63.50 per Baldor share for an overall transaction value of $4.2 billion, including net debt of $1.1 billion. The acquisition is expected to be complete in the first quarter of 2011.

Ecolab Inc. has closed on its previously announced purchase of the assets of the Cleantec business of Campbell Brothers Ltd. , Brisbane, Queensland, Australia.

Chicago-based Berlin Packaging acquired Continental Packaging Solutions, increasing the number of Berlin sales and warehouse locations in North America to more than 70.

Neil McAdam joined World Water Works Inc. as vice president of industrial sales.

Stratas Foods LLC appointed Tedd Kruse to the position of chief executive officer. The Coca-Cola Company Board of Directors elected Howard G. Buffett as a director.

GS1, a non-profit organization that develops supply chain standards, named Kroger COO Rodney McMullen as its chairman. Maines Paper & Food acquired Watertown, NY-based CFM Food Distributors. The tomato business of Violet Packing was acquired by B&G Foods.

Bumble Bee Foods announced the completion of the acquisition of all assets and operations of Bumble Bee Foods from Centre Partners Management LLC by funds advised by Lion Capital LLP. Cargill signed an agreement with Agro Tech Foods Ltd. (India) to acquire its vanaspati (purified hydrogenated vegetable oil) brand Rath. Rath is a leading vanaspati brand in North India and a market leader in the National Capital Region of Delhi.

Nestlé opened a new USD $136 million manufacturing facility in Dubai to serve Nestlé markets across the region.

www.foodengineeringmag.com | Food Engineering | January 2011

19

DESIGNED Results are deÑned by you and Key is designed to help you achieve them: Your quality. Your yield. Your throughput. Your boƷom line. For over 60 years, Key Technology has been delivering valuable automated processing solutions to the food industry. We know our way around your plant operations – from sorters to vibratory conveyors and from graders to dryers. Get the results you want with Key’s innovative ideas and valuable expertise. www.key.net • 509.529.2161 © Key Technology 2010

for results

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

Space: sustainability’s final frontier

`

Container lightweighting and recycled materials are all well and good, but the real action today is in squeezing more units into less space.

C

ontainers that are lighter or perform better are still staples of packaging innovations, and plenty were on display at November’s PACK EXPO show in Chicago. But even when other functional benefits were promoted, shape and the efficient use of space often were the background benefits that translated to the most sustainable savings. Sacramento, CA converter Interpress Technologies collaborated with MeadWestvaco (MWV) Corp. and machine-builder Paper Machinery Corp. to develop a skive and hem process to hermetically seal the seam of paper container linings, making them suitable for foods with moisture or grease levels that otherwise would allow migration out of the container, as well as applications where a reasonable oxygen barrier is necessary. Polyethylene and polypropylene offer varying degrees of integrity, but the best protection comes from MWV barrier board, which weighs half as much as comparable composite materials, according to MWV’s Douglas Reid, marketing director at the Richmond, VA paper supplier.

` Tamper-evident tabs and a skirtless flange are among Trustpack’s functional improvements, but developers expect the space-optimizing shape to be a major draw in winning converts from pails. Source: IPL Inc.

Response to the innovation “was beyond our expectations,” relates Sandy Jaquish, Interpress vice president-sales and marketing. Packagers of cereal, chocolate products and frozen entrées are in the first wave of converts, most of which previously used spiral wound, vertical-wall containers. Those products demanded more atmospheric protection than Interpress was able to provide with its tapered, fiber-based containers, and the improvement enables the manufacturers to leverage Interpress’ key advantage: nestable containers. “Depending on the particular shape, you’re often looking at a 10:1 ratio in space savings,” says Jaquish, which translates to a 90 percent savings in shipping costs for empty containers. The greater savings is on site, not only in storage but also when staging the containers for filling. Tamper evidence was the main design criterion for Trustpack, a new container from Canada’s IPL Inc., Pintendre, QC. A breakaway tab in each corner of the lid provides a clear visual cue once the container is unsealed. A skirtless flange eliminates the potential for contaminating the lip while filling, an issue with a flanged pail, the vessel IPL hopes to replace. But it was the container’s square shape that garnered the most attention when IPL introduced it at the show. Stacked seven layers high, a 40- x 48-in. pallet holds 294 units, compared to 210 2.5-liter pails, according to Jean-Pierre Simard, IPL’s chief marketing officer. “We can get 40 percent more units on a truck compared to cylindrical pails,” adds Simard. The firm debuted a pail with a tamper-evident flange in 1993, but he expects the new shape to replace many of those applications wherever practical. The pails are particularly strong in foodservice, but the ability to do in-mold labeling with high-quality printing should make the squares an attractive option for retail. ❖ For more information: Sandy Jaquish, Interpress Technologies, 916-929-9771, [email protected] Jean-Pierre Simard, IPL Inc., 418-789-3651, [email protected] Douglas Reid, MeadWestvaco Corp., 804-444-7909, [email protected]

www.foodengineeringmag.com | Food Engineering | January 2011

21

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

Happy, happy, joy, joy raphic redesign can be a bear trap for an iconic ` A new, unified look for brand. Doubters need only consider the expe- Kraft’s 50-odd macaroni rience of PepsiCo’s Tropicana, which briefly and cheese products dropped the orange-and-straw graphic two years features a smiley-face ago. The shopper backlash now is regarded as the New Coke logo meant to evoke a of package design in brand-equity circles. blue ribbon from a county Landor Associates’ Mary Zalla was determined to fair. It replaces a design avoid the same trap while directing an overhaul of Kraft created in 1999. Source: Foods’ macaroni and cheese line. The managing director Landor Associates. of Landor’s Cincinnati and Chicago offices conducted a battery of predesign research, including focus groups, eye- brand extensions. Inconsistent graphics led to fragmentation tracking studies and purchase-intent interviews, to enhance of the core brand. At the same time, private-label versions understanding of what attributes customers associated with the appropriated the blue and yellow color scheme, robbing Kraft line. Smiles, happiness and joy were the equity emotions, the macaroni and cheese of some of its distinction. The new logo, which more closely associates Kraft with the product, is being first of which is evident in the package’s smiley noodle logo. “A county fair engages the young, adults and families,” registered as a trademark.. The smiley noodle also is appearing in an integrated marketexplains Zalla. “We were inspired by the metaphor of a county fair and created a brand identity with a circular shape that ing campaign for the brand. “The yellow and blue colors and the Kraft name are the keys,” says Zalla, “and we’re using the noodle evokes a blue ribbon.” Since the last overhaul of Kraft mac and cheese’s box in 1999, to engage people” on billboards and in ads. the Northfield, IL-based company has made multiple line and For more information: Mary Zalla, Landor Associates, 513-419-2300

G

Solutions for you and you alone. No

ceptions.

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

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January 2011 | Food Engineering | www.foodengineeringmag.com

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Geometry drives content

A

rtfully folded paper is the essence of origami. Inventively folded cardboard is the essence of Smurfit-Stone Container Corp.’s Meta boxes. Smurfit-Stone continues to expand its Meta-8 line of box-forming machines, with a case former as the latest addition. The machine addresses the growing retailer demand for displayready cases, according to John Eaton, vice president of automated packaging systems, and it does it with the same precision folding that creates an eight-cornered box with greater vertical compression support despite less material. “We’re a corrugated company that does a lot of machine building,” explains Atlanta-based Eaton, though a quarter century of collaborations with machine-builders such as Douglas Machine were not well known until recent years, when the Meta technology started rolling out. Engineered as a replacement for the regular slotted container (RSC), Meta boxes have a solid bottom and four diagonal columns on the inside wall, creating eight sides, or corners. The corners’ geometry dictates compressive strength, giving shippers the flexibility to match RSC’s strength while using 22 percent less fiber. If higher stacking is desired, a stronger box can

` Eight sides mean eight corners support more vertical compression with less fiber content for produce shippers like Santa Paula, CA-based Calavo Growers Inc.

be folded while still using less fiber than RSC. The machines that form Meta boxes also fabricate conventional boxes and cases, though Meta’s advantages in shipping costs and product protection seemingly would make that flexibility redundant. The cases are formed from die-cut blanks that ship flat, compared to RSC-KD boxes which are formed and glued by the corrugated box manufacturer. For more information: John Eaton, Smurfit-Stone, 678-471-7591, [email protected]

Take a

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with The Shelf Life People.

Take shelf life to the next level with our new EQ-70 gable top Ñlling machine. Developed speciÑcally for mid-size volume markets, the EQ-70 is designed with our exclusive ELL® features to maximize the shelf life of milk, specialty milk products, liquid egg products and still beverages. • Preserve freshness: Environmental control features and carton treatment maintain product quality • Maximize production: Servo-driven features simplify operation n • Gain Ľexibility: Quick and easy changes to Ñll volume, carton heights • Reduce downtime: Easy to operate and maintain

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See Food Master, p. 56

24

January 2011 | Food Engineering | www.foodengineeringmag.com

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

Recession? What recession? Packaging Machinery Spending Outlook

I

f the mood seemed upbeat to visitors and exhibitors at November’s PACK EXPO show in Chicago, it was for good reason: Nine in 10 end-users of packaging machinery report their purchases of additional equipment increased or remained the same in 2010’s third quarter, compared to a year earlier, with food and beverage packagers leading the way. Based on interviews with 147 manufacturers and multiple demand forecasts, the Packaging Machinery Manufacturers Institute (PMMI) predicts slower growth in 2011, “but we do not expect the economy to slip into a double-dip recession,” the Arlington, VA machine-builder association reports. Food manufacturers in particular enjoyed robust production growth in 2010. PMMI estimates food production was up 4.7 percent in 2010, with sugar and confectionery production enjoying 18.6 percent growth over 2009. Expected overall growth in 2011 is 2.1 percent, with 2012 projected to see 3.2 percent growth. The growth forecast for beverages, coffee and tea production was 5.4 percent for 2010, with slower growth of 1.8 percent in

12.9% Increase 32%

32%

Same 55.1% Decrease 12.9%

55.1%

Source: Packaging Machinery Manufacturers Institute.

2011 and 0.4 percent in 2012. Machinery investments by makers of food, beverage and pharmaceutical/medical devices consistently outpace other industrial sectors in PMMI’s forecasts. Assuming favorable economic trends continue, 32 percent of manufacturers polled expect to increase machinery spending in 2011, 55.1 percent expect investments to remain the same, and 12.9 percent anticipate canceling or delaying packaging projects.

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26

January 2011 | Food Engineering | www.foodengineeringmag.com

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FOOD SAFETY

There’s a new sheriff in town

`

It is imperative that processors find out as much as they can about each GFSI audit standard before making a selection.

great deal is happening in the world of food safety. FDA is preparing to issue the modernized GMP proposal. There is a draft proposal to modify acidified foods processing and evaluate processes, and a new food safety proposal affecting the entire industry is forthcoming. However, there’s a new sheriff in town, and that’s the Global Food Safety Initiative (GFSI). This program, driven by major retailers around the world, has the following objectives: • Ensuring food safety • Ensuring consumer protection Richard F. Stier, • Strengthening conContributing Editor sumer confidence • Benchmarking requirements of food safety management, and • Improv ing cost efficiency. Among the retailers that have been instrumental in forming GFSI are the UK’s Sainsbury’s and Tesco, France’s Carrefour, the Netherlands’ Royal Ahold and the United States’ Walmart. Since these companies and others involved are responsible for marketing huge quantities of consumer products, the program has grown rapidly since its formation in 2000. To date, GFSI has approved six audit standards for food processors, each of which includes all of the elements defined by GFSI: • BRC – British Retail Consortium • SQF – Safe Quality Foods • IFS – International Food Standard • Dutch HACCP • FSSC 22000, and • Synergy 22000. The objective of the GFSI audit approval process is to ensure equivalent audits. In other words, if one customer demands a particular audit scheme and another customer demands a different one, the pro-

A

28

January 2011 | Food Engineering | www.foodengineeringmag.com

cessor should (in theory) be able to say it has met the GFSI requirement. Which audit scheme is right for your company? Each scheme focuses on ensuring the production of safe foods by using the hazard analysis critical control point (HACCP) system, and includes prerequisite programs for HACCP. However, each standard is slightly different in set-up and the basic requirements for certification. For example, in BRC, the guidance document states hands must be washed in about 113°F water. Elements that companies should review include: • Audit schedules – How o f te n m u s t the company be certified? Yearly? Every other year? • The proscriptive nature of the audit – Will the company need to change procedures to meet the requirements? • Training/internal certification – Does the company have to hire a consultant or be precertified? • Time – How long will the program take for certification? • Cost – How much will the program and certification cost? It is imperative that processors find out as much as they can about each standard before making a selection. But reading literature on the certification steps is not enough. Processors should also talk to companies that have already completed the certification process about why they selected a certain standard and its value to them. Far too many processors do not do their homework when selecting a standard. They either do what their customers ask or just select a standard. Since there are six approved standards, it should not matter which a processor selects; simply choose the one that is best for your company. ❖

Vibratory Inspection Feeders • Sanitary wash down and quiet operation • Replaces unsanitary belt conveyors

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Bulk-Bag-To-Bin Weigh Batching System discharges, de-lumps and feeds material gravimetrically

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Half Frame Unloaders with Conveyor or Airlock require forklift, eliminating cost of upper frame

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TECHNOLOGY S O U R C E B O O K Focus on PACK EXPO Show Products

METAL DETECTOR Conforming to traceable event recording guidelines under FDA Title 21, the Heat and Control CEIA THS 21e metal detector continuously tests and calibrates itself to maintain inspection performance. Its 1-button sensitivity preview provides an estimate of the size and contaminant material the detector is expected to identify. Bluetooth connectivity eliminates the need to access the detector’s interior for programming and data collection; Ethernet connection is also available. Single- and 3-frequency models feature an electronic platform and a stainless steel casing and keyboard. Conformalcoated circuit boards make the unit suitable for IP65K washdowns. Heat and Control, Inc.; 800-227-5980; www.heatandcontrol.com configuration designed into the valve, more or less steam is permitted to escape. Applied at the package converting stage, the valve is clear, and can be printed with 1-color text, graphics and logos. Avery Dennison; www.averydennison.com

SANITARY PROBES OMEGA PRS-TMM12 sanitary probes with integral transmitter and M12 connector are designed for use in sanitary or hygienic clean-in-place applications in the food, dairy and beverage industries. Manufactured with 316L stainless steel housings that meet the dimensional and finish requirements of 3-A Standard 74-03 and ASME BPE-2007, the probes are welded and processed to provide a 32 micro-inch or better surface finish in the wetted areas for CIP processes. OMEGA ENGINEERING, INC.; 203359-1660; www.omega.com

BATCH ADDITION SYSTEMS TOUCH SCREEN PANEL

STEAM VALVE Used for precooked foods such as sauces, rice, dumplings and noodles, the Avery Dennison Flexis Steam self-venting valve actuates at a predetermined temperature during the cooking process to allow a precise amount of steam to escape from the package. Depending on the baffle

Compatible with all Fortress Phantom metal detectors, the Fortress ICON touch screen panel uses Quad-Core processing to detect metal contaminants and provide detailed data collection. Information gathered such as product configurations, rejects and faults is stored in an onboard database and is accessible via USB; it can be exported in Microsoft Excel or Adobe Acrobat PDF file formats. Fortress Technology; 888-220-8737; www.fortresstechnology.com

Oden batch addition systems provide fully and semi-automatic or multiple-channel precision liquid product metering. Available as mass meter and loss-in-weight scale-based systems for net weight applications or SPC requirements, they meter and dose color, fragrance, vitamins and ingredients. The systems come with a choice of factory-standard OEM component brands and full installation, integration and commissioning support. Oden Corporation; 800-658-3622; www.odencorp.com

www.foodengineeringmag.com | Food Engineering | January 2011

31

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

your operations and improve visibility efﬁciency and ﬂexibility

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costs time to market sReduce your carbon footprint sSpeed

Register Today For ProMat 2011! Find free registration, detailed exhibitor information, educational session details, show news and your customized My ProMat Show Planner at www.ProMatShow.com or call 800-446-2622 or 704-676-1186.

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TECHNOLOGY S O U R C E B O O K

PACKAGE FORMAT Suitable for cereals, snacks, baking supplies, frozen foods and pet treats, the Zip-Pak Zipbox package format combines the structural benefits of traditional cartons with the convenience and resealability of flexible pouches. Zip-Pak; www.zippak.com

BREAST CAP DEBONER Capable of deboning up to 2,400 breast caps/hr., the Foodmate FM 7.40 breast cap deboning machine produces single and butterfly filets. It features an automatic skinning and blister remover, and its design allows adding a transport belt under the machine. Constructed with stainless steel and food-approved nylon for hygiene, the unit is equipped with a stainless steel washdown motor. Foodmate; www.foodmate.nl

HEAT EXCHANGER Engineered for applications such as cooking, heating, cooling, slush freezing, crystallization, pasteurization and sterilization, the Terlet Terlotherm vertical scraped-surface heat exchanger can be used with creams, fruits, soups and sauces, as well as confectionery, meat, dairy and other food products. The unit has a hinged top cover that allows inspection and cleaning without disturbing the single shaft seal and 1-piece scraper blades that can be replaced without tools. Terlet; 856-241-9970; www.terlotherm.com

CONSTANT-MOTION CARTONER Achieving speeds up to 400 cartons/ min., the OYSTAR Jones Legacy 3 constant-motion small-center cartoner has an ergonomically designed straight-in, lowlevel carton magazine; a balcony design to maximize accessibility to all areas of the machine; tool-less adjustments and changeover points; and a variable-velocity carton feed design that utilizes an opposed vacuum pre-opening system. R.A. Jones & Co. Inc.; www.oystar.rajones.com

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 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 CARTON FORMER The Kliklok-Woodman TransFormer top-load carton former allows lockstyle and glue-style cartons to be run on the same machine at up to 120 cpm with a single head. It features a servo rainbow friction feeder; an ergonomic, waist-level hopper; a micro-touch screen HMI; and a servodriven, high-precision THK linear rail head mounting system for absolute head-to-cavity positioning. Kliklok-Woodman; 770-981-5200; www.kliklokwoodman.com

www.foodengineeringmag.com | Food Engineering | January 2011

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.

Register Today! www.ProMatShow.com

TECHNOLOGY S O U R C E B O O K

EYE-LINK BELTS Lightweight and positively driven, Ashworth Eye-Link straightrunning conveyor belts feature eye-links that make up the flat, even surface; the overall construction provides a rigid structure that resists side-to-side deflection while enabling the belt to handle thousands of pounds of tension. The belts are positively driven by rollers, sprockets or a chain edge. Suited for a range of applications, the belts are available in numerous configurations of pitch spacing, wire diameter and mesh designs. Options include cross flights, side plates, chain edges and additional bar links. Ashworth Bros., Inc.; 800-682-4594; www.ashworth.com

34

January 2011 | Food Engineering | www.foodengineeringmag.com

CASE PALLETIZER The Intelligrated Alvey 890 mid-speed case palletizer forms virtually any pattern, including 4 different layer configurations in one load, with a wide range of package types and sizes on a variety of pallet platforms. Capable of rates up to 75 cases/min., the palletizer features enhanced diagnostics and alarm history, standard Ethernet communication capabilities and fully integrated safety guarding with Category 3 controls. Intelligrated; www.intelligrated.com

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TECHNOLOGY S O U R C E B O O K

RETORT SOFTWARE

CASE SCALE

Allpax Maintainer software automatically tracks critical retort components and alerts personnel when the components are scheduled for maintenance; it also provides retort room personnel with quick access to machine documentation, maintenance tech notes and 3D views of retort components. Allpax Challenger software monitors critical operating parameters and reporting on any point of deviation from norms during the retort process. Allpax Products; 888-893-9277; www.allpax.com

The Ossid CS100 NTEP-certified case scale achieves a throughput of up to 45 cases/min. It features a Microsoft SQL Database, network connectivity through wired or wireless Ethernet, automatic download of product recipes to other line devices, an open architecture Windows-based operating system and 15-in. color touch screen that supports multiple languages. It handles cases weighing up to 100 lbs and measuring up to 27.5-in. wide and 29.5-in. long. Ossid; 800-334-8369; www.ossid.com

Rejection is Good It is when you want to protect your equipment and keep your product pure.

Quicktron 05 RH

Our Quicktron 05 RH Metal Detector is designed to detect and reject metal contaminants from free falling bulk materials without interruption of production. The Quicktron 05 RH is perfectly designed for food manufacturers because it is constructed to perform at a high food processing level and gives a facility a superior hygienic processing capability.

Always Your Best Choice...We’ll Prove It!

800-835-2526 316-284-2020

or

buntingmagnetics.com

(outside USA or Canada)

Email: [email protected] See Food Master, p. 25

magnets 36

|

separation

|

conveyors

|

January 2011 | Food Engineering | www.foodengineeringmag.com

metal detection

©2010 Bunting® Magnetics Co. BUNT-112910-2

|

cylinders

|

flexible dies

Reliable Under Pressure

Baldor washdown duty motors, drives, gear products and mounted bearings thrive under high pressure, caustic cleaning conditions. Designed for food, beverage and pharmaceutical processing, our products add high performance and superior reliability to the toughest applications.

• Energy Efficient

With more than one million washdown motors in service, no other manufacturer offers more choices or better performance under pressure.

• Superior Reliability

baldor.com

• Quickest Delivery Available

479-646-4711

©2010 Baldor Electric Company

• Unmatched Quality

TECHNOLOGY S O U R C E B O O K

DUAL-SHAFT MIXER Designed to mix medium-high viscosity products up to approximately one million centipoises, the Ross laboratory dual-shaft mixer provides a combination of low- and highspeed agitation. It has a reverse vertical lift to raise the mix can to mixing position; self-contained control panel, including a single point hook-up; variable-speed controls and inverter duty motors; and dual-handed raise and lower controls. Charles Ross & Son Company; 1-800-243-ROSS

MODULAR SUCTION CUP Available with a range of independent lips, bellows and fittings in sizes from 25 to 77mm, the Piab piGRIP modular suction cup can be tailored to individual gripping, lifting and height requirements to handle a variety of products and fit with a number of packaging machines, including robotic arms, rotary cartoners, labeling machines and carton erectors. Piab; www.piab.com

BELT COATER The Schebler Revolv belt coater has a triple-drip manifold that provides the ability to run multiple coatings of milk, dark and white chocolate; it can be hooked up to 3 coating tanks at the same time. Operators can automatically switch from tank to tank with no cross-contamination. An optional belt heater eliminates the need to scrape the belt between runs and allows residual coating left on the belt after the last batch dose has been distributed to be reclaimed onto the product. Schebler Food Equipment; 563-359-0110; www.schebler.com

January 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

ROTARY RING STRETCH WRAPPERS Phoenix rotary ring automatic (PRRA) pallet stretch wrappers eliminate the need for extra film passes up the load to secure top wraps and then back down to the clamp for final tail treatment. Able to start and stop the cycle anywhere on the load, the wrappers allow virtually unlimited wrap patterns. The PRRA-4000 model offers 40rpm, 100+ loads/hr.; the PRRA-2100 wrapper offers 21rpm, 70+ loads/hr. Phoenix Innotech; 514-956-1525; www.phoenixwrappers.com

MOTION CONVEYOR The tna roflo 3 electromagnetically driven horizontal motion conveyor has a gateless design to gently transport product. Totally reversible, it changes the way multiple pans connect, allowing simultaneous movement of product in several directions on just one line. tna; www.tnasolutions.com

ROBOTIC PLATFORM Designed for next-generation high-speed primary packaging applications requiring both flexible and sanitary processing, the Adept packaging automation cell is built with a rigid, stainless steel frame and integrated with products such as ultra-compact motion and vision controllers, touch screen operator interface and predefined programming recipes for conveyor-tracking and vision-guidance. Adept Technology, Inc.; www.adept.com

BLOW-MOLDED CONTAINERS Sonoco blow-molded bottles and containers are manufactured using 1- and 2-step injection stretch blow-molding and monolayer and multi-layer extrusion technologies. 3D CAD-engineered custom bottle design and decorating with pressure-sensitive and heat-transfer labeling, silk screen and shrink sleeves are available. Sonoco Plastics; www.sonoco.com

www.foodengineeringmag.com | Food Engineering | January 2011

TECHNOLOGY

Shaft Alignment

S O U R C E B O O K

& Geometric Measurement

PALLETIZING SYSTEM Rotalign® ULTRA

Vibration Analysis

& Balancing

h WatcOS VIDEine Onl

The Westfalia dairy case palletizing system can handle both plastic and wood pallets; it palletizes 2 full pallets/min. Each pallet holds 9 stacks of dairy cases, stacked 6 high, for a total of 54 cases. Constructed of all-stainless steel materials, it is suited for the washdown environments found in the dairy and beverage industries. Westfalia Technologies, Inc.; 800-673-2522; www.westfaliausa.com Motorized adjustment points make case format changeovers completely automatic. Gripping/transfer tooling includes the rotation function necessary to build required pallet patterns. A mobile cubicle partition, which is slid between the two palletizing stations by the unit’s telescopic arm, enables handling full and empty pallets without stopping the machine cycle. Cermex; www.cermexinc.com

SUSTAINABLE PACKAGING

VIBXPERT® II

Easy-to-use solutions for your maintenance needs! Sales • Rentals • Services

305-591-8935 • www.ludeca.com

PACKING/PALLETIZING UNIT Combining an SD58 top-loading module with a P5 palletizing module, the Cermex SD/P5 Combi case packing and palletizing unit has a completely modular design. Integrating a range of loading arms, the combined unit handles packaging throughout each phase.

Suitable for ready-to-serve meals that can be taken from the freezer to the table via either a microwave or conventional oven, Huhtamaki Ovenware II trays are made 100 percent preconsumer fiber. The trays can be custom-molded into various sizes, shapes or configurations, with any number of compartments. They can be embossed with a logo or printed with a brandspecific or promotional image; the tray fibers can also be tinted. Huhtamaki; www.us.huhtamaki.com

January 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

Hixson, one of the leading design and engineering ﬁrms in North America, is proud to sponsor the Food Plant of the Future webinar series. This webinar series is intended to provide engineering and operations executives with insights and technology solutions to many of the critical issues facing food and beverage processors. The following webinars are now archived: Surviving and Thriving with Automation Advancing Food Safety through Sanitary Design Building Realistic Sustainability into Food and Beverage Plants Access these and other archived webinars and learn about what’s coming next at www.foodplantofthefuture.com.

DETECTION SYSTEM Combining the Lippke 4000 series and hand-held Pac Check 302 oxygen headspace analyzer, the MOCON MultiCheck 300 system detects leaks and measures oxygen headspace and seal strength. Headspace results are available in seconds. As soon as that measurement is complete, the system software switches a valve to begin either leak detection, seal strength or both. Suited for a broad spectrum of shelf life-sensitive food products, the system can be used to test a variety of packages including flexible, rigid and composites. MOCON, Inc.; www.mocon.com

CONDITION ANALYSIS TOOL The Key RemoteMD real-time condition analysis tool monitors the condition of a G6 optical sorter or G6 automatic defect removal system, assesses the status and alerts users if problems are detected. The basic unit, available as part of the Select PRO protection plan, includes system monitoring, alarms for critical events, remote diagnosis, remote fixes and software management. Additional services such as remote auditing, remote back-ups, proactive log analysis, product metrics tracking and segmentation assistance are available as part of the PlusPRO or PremierPRO protection plan. Key Technology, Inc.; www.key.net

Hixson 659 Van Meter Street Cincinnati, OH 45202 www.hixson-inc.com T: 513-241-1230 Email: [email protected]

ROLL-UP DOOR LUBRICANT CRC roll-up door lubricant eliminates noise from squeaky rollers and hinges; it prevents friction and wear, and leaves a thin film to protect against rust and corrosion. The lubricant displaces moisture and protects

metal components found on roll-up and overhead door assemblies for up to 9 months indoors. NSF H2 registered for use in meat and poultry plants, it comes in a 16-oz. aerosol can with a 360° valve so it can be sprayed from any position. CRC Industries; 800-272-4620; www.crcindustries.com

CHIP VACUUM Used on fixtures, floors and work surfaces of machining centers, lathes, saws, mills and other industrial equipment, the EXAIR Model 6193-30 30-gal. compressed air-powered Chip Vac system picks up metal, wood and plastic chips and delivers them to an ordinary 30-gal. drum. The system includes a shutoff valve, 0.1 micron filter bag, drum lid with locking ring, 10-ft. flexible vacuum hose, aluminum chip wand, 2 extension wands, crevice tool, brush, skimmer and floor tool. EXAIR Corporation; 800-903-9247; www.exair.com

January 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

AUTOMATION CONTROLLERS Using the same configuration, networking and visualization environment as larger-scale systems, Rockwell Allen-Bradley Compact GuardLogix programmable automation controllers provide integrated safety, motion, discrete and drive control capabilities in a single control platform. Featuring a 1oo2 safety architecture, the controllers are rated up to Safety Integrity Level 3. Rockwell Automation, Inc.; www.rockwellautomation.com

CHEESE SHREDDER Featuring easily interchangeable cutting heads and a 32-in. cutting zone enclosure, the Urschel Model CC-DL cheese shredder offers a variety of slices, shreds, grating options and strip cuts. It comes standard with a 10hp motor and swing-away feed hopper to simplify cutting head changeovers. Urschel Laboratories, Inc.; 219-464-4811; www.urschel.com

CASE PACKER Designed for heavy-duty applications, the Schneider wraparound case packer uses servo motion to build cases around products and seal the manufacturer’s joint. Stainless steel slugged construction allows complete washdowns for food packaging. Schneider Packaging Equipment Co.; 315-676-3035; www.schneiderequip.com

REMOTE ACCESS PLATFORM The eWON Talk2M Web-based remote access platform gives single-click, secure, on-demand Internet access to remote machines, PLCs and sites worldwide. Combined with eWON Internet remote access devices, it enables integration with a variety of PLCs and automated devices. eWON; www.ewon.us

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January 2011 | Food Engineering | www.foodengineeringmag.com

HEAVY-DUTY CYLINDERS Engineered for heavy-duty industrial operations, TRD MH Series and TAS Series cylinders feature a heavyduty rod wiper, seals, wear band and chrome-plated ID tube; rod locks, stop tubes, center supports, stainless steel piston rods and high-impact pistons are available as performance options. MH Series medium-pressure hydraulic cylinders are rated for 675 to 1500psi (depending on bore size). TAS Series steel pneumatic cylinders are rated for 250psi air and 400psi hydraulic (with TH option). Both models are available in bore sizes 1.50, 2, 2.50, 3.25, 4, 5, 6 and 8 in. TRD Manufacturing; 815-654-7775; www.trdmfg.com

TECHNOLOGY S O U R C E B O O K

PRINTING SYSTEM Specifically for packaging applications, the Xennia Aquamarine printing system provides high-quality, multicolor batch printing of EPS fishboxes, chill boxes, cartons and other secondary packaging. It features high-speed, single-pass printing and full variable data capability with a 4.7-in. print height and print speeds up to 1,800 boxes/hr. Xennia Technology Ltd; www.xennia.com

METAL-DETECTABLE EARPLUGS

ARTICULATED ROBOT A fully automatic articulated robot, the BEUMER robotpac performs complex palletizing and depalletizing tasks. Regulated by complex control mechanisms, the robot stacks packaged goods of variable dimensions on one pallet. Individual programs cover all packing patterns; the switch from one program to another is accomplished with the push of a button. Multiple gripping systems are available including a fork gripper and double-fork gripper; a finger gripper and double-finger gripper; and a suction gripper. The BEUMER Group; www.beumer.com

STRETCH WRAPPER Designed for high-volume applications requiring throughput speeds ranging from 90 to 130 pallets/hr., the Lantech high-speed ring straddle stretch wrapper has a No Film Break film delivery system, containment management system, pallet grip and pressand-seal film clamp to eliminate film breaks, uneven containment force, loads not bonded to pallets and film tails. The containment management and visual management systems provide machine-generated data on the quality of the stretch wrapping and the performance of the equipment. Lantech.com; 800-866-0322; www.lantech.com

Jackson Safety H10 and H20 metaldetectable disposable and reusable earplugs have embedded metal to ensure they can be easily detected via scanning; the earplugs are a distinctive blue color for effective compliance monitoring and increased visibility. Kimberly-Clark Professional; www.kcprofessional.com

ROLL-FED LABELER Suitable for medium- and high-capacity ranges, the KHS Innoket 360 rollfed labeler has self-sharpening cutters housed in a warp-resistant cast iron frame and a segmented vacuum drum that reduces the handling weight from 22 to 6kg. It features an ergonomic design, glue tank and gluing roller designed as a complete system. KHS USA, Inc.; www.khs.com/us

www.foodengineeringmag.com | Food Engineering | January 2011

45

C O M PA R E

SIX BULK FOOD BLENDERS AGAINST YOUR SPECIFIC NEEDS Excellent

Good

Fair BATCH

Poor

The ratings below are generalizations that do not apply to all applications. Please consult factory for specific equipment recommendations.

CONTINUOUS

Spices

Spices

Starches

Starches

Flakes

Flakes Crystals

Coffee/Tea

Coffee/Tea

Fibrous Materials

Fibrous Materials

Fragile Materials

Fragile Materials

Grains

Grains

Large Variance In Particle Sizes

Large Variance In Particle Sizes

Emulsions/Pastes

Emulsions/Pastes

Agglomerates/Pellets

Agglomerates/Pellets

Powders

Powders

Slurries

Slurries

Sticky/Tacky Materials

MATERIAL REQUIREMENTS

MATERIAL REQUIREMENTS

Crystals

Sticky/Tacky Materials Complete Discharge

Gentle Blending

Gentle Blending

Low Maintenance

Low Maintenance

Lowest Energy/Amt Blended

Lowest Energy/Amt Blended

Lowest Initial Cost

Lowest Initial Cost

Rapid Blending

Rapid Blending

Rapid Sanitizing

Rapid Sanitizing

Uniform Blending

Uniform Blending

Uniform Liquid Additions

Uniform Liquid Additions

EQUIPMENT REQUIREMENTS

EQUIPMENT REQUIREMENTS

Complete Discharge

FOR OBJECTIVE ADVICE ASK THE ONLY MANUFACTURER OF ALL SIX BLENDERS No blender is best at everything. Which is why you should specify your requirements before specifying your blender. Problem is, most manufacturers make only one or two kinds of bulk food blenders, so objective advice about the best one for you may be hard to find. But Munson manufactures eight types of blenders, six of which are shown above—and offers free lab

testing on them all. So in addition to being objective, Munson can tell you precisely how effective—or ineffective—each blender would be at meeting your specific cost and performance requirements.

MUNSON MACHINERY CO., INC.

So before you price-out a blender, spec it out with the expert help of a Munson engineer— at no cost or obligation. And take the risk out of buying a blender.

W W W. M U N S O N M A C H I N E R Y. C O M

+1-315-797-0090 USA: 1-800-944-6644 I N F O @ M U N S O N M A C H I N E R Y. C O M

V-1168

C O M PA R E

SIZE REDUCTION EQUIPMENT AGAINST YOUR SPECIFIC NEEDS Excellent

Good

Fair

Not Recommended

The ratings below are generalizations that do not apply to all applications. Please consult factory for specific equipment recommendations.

Powders

Powders

Crystals

Crystals

Flakes

Flakes Fibrous Materials

Granules

Granules

Large Agglomerates

Large Agglomerates

Frozen Vegetables

Frozen Vegetables

Dried Pastas

Dried Pastas

Coffee Beans

Coffee Beans

Tea Leaves

Tea Leaves

Dehydrated Fruits

Dehydrated Fruits

Nuts

MATERIAL REQUIREMENTS

MATERIAL REQUIREMENTS

Fibrous Materials

Nuts

Spices

Spices

Grains

Grains

Fine Grinding (<40 mesh)

Fine Grinding (<40 mesh) Medium Grinding (8-40 mesh)

Coarse Grinding (4-8 mesh)

Coarse Grinding (4-8 mesh)

Bulk Reduction (>4 mesh)

Bulk Reduction (>4 mesh)

Controllable Sizing

Controllable Sizing

Sanitary Designs

Sanitary Designs

Classification

Classification

Maintenance

Maintenance

High Throughput

High Throughput

Durability

EQUIPMENT REQUIREMENTS

EQUIPMENT REQUIREMENTS

Medium Grinding (8-40 mesh)

Durability

FOR OBJECTIVE ADVICE ASK THE ONLY MANUFACTURER OF ALL SIX T YPES No single piece of size reduction equipment is best at everything. Which is why you should specify your requirements before specifying your equipment. Problem is, most manufacturers make only one or two kinds of size reduction equipment, so objective advice about the best one for you may be hard to find. But Munson manufactures 10 types, six of which are shown above—and offers free lab

testing on them all. So in addition to being objective, Munson can tell you precisely how effective—or ineffective—each type would be at meeting your specific cost and performance requirements.

MUNSON MACHINERY CO., INC.

So before you price-out size reduction equipment, spec it out with the expert help of a Munson engineer—at no cost or obligation. And take the risk out of buying size reduction equipment.

W W W. M U N S O N M A C H I N E R Y. C O M

+1-315-797-0090 USA: 1-800-944-6644 I N F O @ M U N S O N M A C H I N E R Y. C O M

Y-1170

GET RECESSIONFIGHTING SAVINGS WITH CLAYTON STEAM BOILERS

TECHNOLOGY S O U R C E B O O K

TRAP-PRINTED FILM

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

Sealed Air Cryovac trap-printed film produces finished packages from 3- to 24-oz. for sauces, glazes and gravies to accompany meal kits or meats. Designed to run on high-speed Onpack VFFS systems, the film is made of multi-layer coextruded films laminated with print between the layers. Available in white and clear versions with 8-color print capacity, the film allows printing cooking directions and recipes directly on packages. Sealed Air; 800-391-5645; www.sealedair.com

TURNS LIME SCALE INTO A GAS It is safe for employees, equipment and the environment. NSF A3 approved • Biodegradable • Non-Corrosive, Non-Flammable • Changes color when spent.

www.sublimedescaler.com

The industrial strength solution to remove oil and grease Environmently safe • Water based • Biodegradable NSF Registered A8 and C1

SUMMIT INDUSTRIAL PRODUCTS P.O. Box 131359 • Tyler, Texas 75713

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

800.749.5823 [email protected]

www.klsummit.com January 2011 | Food Engineering | www.foodengineeringmag.com

Rugged. Clean. Precise.

Process control has never looked so good. Visit us at th e Internationa l Poultry E xp o Booth #63 56

ELEMENT is a complete system approach that allows complete solutions to process problems. It encompasses the total loop: valves, sensors and controllers in one beautifully simple architecture which can be relied on to monitor and control inert ﬂuids, steam, corrosive solvents, chemicals or abrasive ﬂuids in a wide variety of application environments.

For more information: (800) 325-1405 or www.burkert-usa.com

TECHNOLOGY S O U R C E B O O K

LIGHT STRIP CASE PACKER Designed for the high-speed packing of fragile containers, the Standard-Knapp Versatron case packer has Soft Catch technology that reduces shock energy by 80 percent over a conventional drop packer, enabling the use of thinner gauge bottles and thinner glass. A 2-axis servo system allows the packer to catch the product as it descends into the case. The lift table moves the case to the “up” position and waits for a full grid. When the grid is full, the riding strips shift to the side and initiate the bottle descent. Standard-Knapp; 860-342-1100; www.standard-knapp.com

A low-profile, energy-efficient lighting solution for industrial control cabinets and work cells, the Banner WLS28 solid-state LED work light strip provides bright, long-lasting illumination inside enclosures and other areas with poor lighting conditions. In applications where multiple lights are required, the light strips can be cascaded end-to-end. Swivel mounting brackets are included to allow pivoting the light 45° in either direction. Available in lengths from 5.7 to 44.5 in., each light strip is 1.1in. wide. Banner Engineering Corp.; 888-373-6767; www.bannerengineering.com

Cablevey is a registered trademark of Intraco, Inc. 09/2010

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January 2011 | Food Engineering | www.foodengineeringmag.com

Experts in Spray Technology Spray Nozzles

GunJet® Spray Guns ensure water is "on" only when needed

Spray Control

Spray Analysis

Spray Fabrication

Change the Way You Spray To Use Less Water We have dozens of ways to help you consume less water without compromising performance. Here are just a few: U Use automated tank washers to clean tanks and vats. Water savings are typically significant – millions of gallons per year U Replace open hoses with spray guns and reduce water consumption by 50% or more U Use spray manifolds equipped with nozzles instead of pipes with holes to reduce water use by as much as 50% U Inspect and replace worn spray nozzles on a regular basis – water waste from even slightly worn nozzles can easily reach hundreds of gallons per hour

Learn More at spray.com/foodprocessing Request these helpful publications or visit our web site for more ways to save water. U Change the Way You Spray to Maximize Water Conservation, Technical Manual 415 U A Guide to Safe and Effective Sanitation, Catalog 40

Spray manifolds with nozzles provide precise coverage and minimize waste

See Food Master, p. 136-137

1-800-95-SPRAY | spray.com |

Nozzles that appear to be in good condition may be worn and spraying significantly over capacity

Tank washers and tank wash nozzles use a fraction of the amount of water than manual and fill and drain cleaning methods

Specify and order standard nozzles spray.com/ispray

TECHNOLOGY

YES, YOU CAN:

S O U R C E B O O K

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

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

X-0821

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

IN-LINE SLEEVERS Eliminating the need to turn packs, Ravenwood Nobac 400 and Nobac 500 in-line linerless sleevers can apply sleeves in a number of formats including top, top and side, top and 2 sides, C-wrap and full wrap as well as the wrapping of irregular packs such as whole birds. They control both ends of the label in the feed system to improve positional accuracy of the label around the package. Ravenwood Packaging; ravenwoodpackaging.com

AUTOMATIC TUBE FILLER Intended for small-to-medium size batches, the Romaco Unipac U 2060 automatic tube filler has an enclosed design and a less than 1.5 square meter footprint. Equipped with 8 stations, the unit fills semi-solids such creams, gels and pastes into aluminum, laminate or polyethylene tubes that are closed mechanically by a series of folds or in a heat sealing or hot air process. Romaco Group; www.romaco.com

BUTTON-STYLE POINTER The CTI compact OM20U2 Orbital Mouse pointer has factory settings for 8 speed curves. A low profile makes it suitable for limited space situations such as instrumentation equipment, outdoor monitoring or surveillance equipment, or handheld mobile devices. NEMA 4 (IP 66) environmental sealing eliminates moisture and dirt contaminants, and protects the unit against harsh chemicals, oils and solvents. CTI Electronics; 203-386-9779; www.ctielectronics.com

January 2011 | Food Engineering | www.foodengineeringmag.com FEX03074Mart_1.indd 1

2/21/07 2:43:26 PM

TECHNOLOGY S O U R C E B O O K

Product Delivered. Just Right.

DRUM OVENS Used to heat drums and totes of viscous or solid material up to a pumpable or pourable temperature, Benko Sahara Hot Box drum ovens have low-watt density heating elements and an industrial digital temperature controller, with an independent high-temperature cutoff to prevent overheating. They come standard with all-steel construction; models with 304 stainless steel construction are also available. Optional control system features include Ethernet or serial Bus communication; and profile temperature control with ramp and hold capability, ranging from 8 profiles with 3 steps to 64 profiles with 64 steps. Benko Products, Inc.; 440-934-2180; www.benkoproducts.com

BAND SEALERS Available in a range of styles and options, Bosch B-550 series band sealers come in vertical and horizontal formats and 2 feed directions. The drive motor has variable-frequency speed control, with a maximum production speed of 1,000 in./min. Full-length 12mm urethane timing belts grip the bag top and provide positive timing and speed control throughout the length of the sealer. Compression wheels create seals on gusseted and difficult-to-seal films. Standard options include emboss or ink coders, integrated conveyors, bag top trimmers, bag counters and stainless steel construction. Bosch Packaging Technology; www.boschpackaging.com

Segregation Free. Damage Free. Abrasion Free. Dense Phase Vacuum Conveying. You can rely on Volkmann high quality, vacuum conveying systems to deliver your product just right, no matter where it needs to go. Designed for safe product transfer and ease of use, you’ll ﬁnd Volkmann conveyors simple to use, clean, maintain and install. Call today to set up your product demonstration and see what Volkmann can do for you.

Sanitary, Safe, Trouble-Free Vacuum Conveying

4-AXIS ROBOT Suitable for a range of packing applications, the Motoman MPK50 4-axis high-speed robot features a 110.3-lb. payload and a 360° work envelope. The floor-mounted robot has a 65.7-in. vertical reach, 78.6-in. horizontal reach and ±0.5 0.02-in. repeatability; 39.9 in. wide, it can work in close proximity with conveyors and other equipment. Motoman Robotics; www.motoman.com

www.foodengineeringmag.com | Food Engineering | January 2011

609-265-0101 www.volkmannUSA.com

TECHNOLOGY S O U R C E B O O K

AXIAL FLOW IMPELLER

MOTION CONTROL SYSTEM

Suitable for heat transfer, blending and solids suspension applications, the Chemineer XE-3 high-efficiency axial flow impeller has a mechanical design that reduces weight, allowing longer shafts without the need for additional support. Available in carbon steel, 316/316L stainless steel, high alloys and with an array of coatings, the impeller can be used in both new and retrofit applications from lab- to full-scale operations. Chemineer; 937-454-3200; www.chemineer.com

The Siemens Simotion P320-3 motion control system includes an embedded PC that has a DDR3 memory and Intel Core2 processor, and is free of wear from moving parts such as hard disks and fans. Accommodating centralized or decentralized machine concepts for PC-based applications or applications that require a compact size, the system has multiple onboard interfaces for a range of motion control applications. Siemens; 800-879-8079; www.usa.siemens.com

Sine pumps - gentle and reliable for meat, fish and poultry • No pulsation or meshing rotors, will not damage whole meats • Pump product evenly onto conveyors to reduce cost of manual sorting • Less marinade loss provides for a higher yield • Simple, quick and easy to clean

Com e Poul see us a boot tr y Expo t h #6 359

Food and Beverage Division Watson-Marlow

54

MasoSine

Bredel

January 2011 | Food Engineering | www.foodengineeringmag.com

www.masosine.com See Food Master, p. 129

800-282-8823

TECHNOLOGY S O U R C E B O O K

DELTA ROBOT The ABB IRB 360 FlexPicker second-generation delta robot is available in long-, standard- and compact-reach models to meet payload/performance, working range and sanitation requirements for a wide range of applications. A fifth-axis version can pick flat product and reorient it in an on-edge position at the high speeds commensurate with standard pick-and-place operations. ABB Robotics; 248-391-9000; www.abb.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.

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January 2011 | Food Engineering | www.foodengineeringmag.com

MIXER/GRINDER Featuring a 225-lb. hopper with a counterbalanced safety interlocked lid, the Hollymatic 180A mixer/grinder has a stainless steel “figure 8” mixing paddle that blends fat to lean and a minimum-exposed feed screw that prevents temperature rise in high-speed ground meat production. The unit’s hopper tilts for cleaning and onetool disassembly of the mixing paddle, grinding head and feed screw for sanitizing purposes. Hollymatic; 708-579-3700; www.hollymatic.com

MERGE CONVEYOR Handling various types of packages including formed shells, trays and forms, and fill and seal bags and pouches, the Nercon Live Roller metering and merging conveyor “stalls” products until they are in proper sequence; it then meters and merges them without the use of clamps, stops or sophisticated controls. A downstream exciter belt drives the primary belt’s rollers in a backward spinning motion. Products float on the roller sections briefly until a rollerless chain section emerges, putting the product in forward motion traveling on an indexing pocket. Simple plow rails or powered side rails merge multiple lanes into a single file; the unit also can be configured as a multiple-lane unit with indexing pockets arranged in a staggered pattern. Nercon Engineering & Mfg., Inc.; www.nercon.com

TECHNOLOGY S O U R C E B O O K

THERMAL PRINTER

BARRIER FILM

The Open Date Thermocode iQ thermal printer has a 7-in. touch screen that allows users to edit print images and adjust print settings, including during use; print images and program updates can be downloaded through the printer’s TCP/IP network connection or its USB port. The unit is electronically driven by 3 stepper motors that provide up to 800 print cycles/min. The printer can run on all intermittent labellers and packaging machines, at a speed of 24 in. per second. Open Date Systems Inc; 603-763-3444; www.opendate.com

Suitable for a variety of granular, powdered, liquid and solid products, Rollprint Overture One non-aluminum-foil barrier film is designed for stick pack and flow wrapped applications. Oxygen barrier levels are available as low as 0.0008cc/100in.2/24 hrs.; moisture barrier properties are available down to 0.0008g/100in.2/24 hrs. The film can be used to keep an entire structure transparent or as a window to display package contents. Rollprint Packaging Products, Inc.; www.rollprint.com

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

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

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January 2011 | Food Engineering | www.foodengineeringmag.com

Schenck AccuRate is a unit of Schenck Process

©2009 Schenck AccuRate

TECHNOLOGY S O U R C E B O O K

TOP CASE SEALER Capable of achieving speeds to 25 cpm, the A-B-C Model 136HM compact, adhesive top case sealer features a heavy-gauge stainless steel frame, continuous motion side belt case drive, contoured flap folders and flexible roller compression section. Built for dropin installation, the sealer is built to standard 15-in. line elevation, and has independently adjustable footpads for leveling on all floor surfaces. The unit adjusts to case sizes from 8 in. x 6 in. x 5.25 in. to 24 in. x 16 in. x 17 in. A tape-sealing model is also available. A-B-C Packaging Machine Corporation; 800-237-5975; www.abcpackaging.com

INDUCTION CAP SEALER Offering high-speed sealing capabilities, the Enercon Super SealTouch induction cap sealer is a completely integrated inspection system, with an intuitively designed touch screen interface, simplified set-up and operation, and a range of capabilities for internal monitoring and remote network communications. The system ships with an operator-friendly quick-start guide. Enercon Industries Corporation; 262-255-6070; www.enerconind.com

Optimal Effectiveness for Optimal Results: We Have All the Options Mepaco is an industry-leading provider of thermal processing, grinding, mixing/blending and material handling products. Our best-in-class equipment and service offer food-processing solutions designed to ﬁt your unique needs. And because efﬁciency is more important than ever, our entire line is built for optimal effectiveness to ensure minimal downtime, desired throughput and high-quality end products. Our unwavering service, reliability and technical leadership come standard with all of our products.

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59

TECHNOLOGY S O U R C E B O O K

ROTARY VALVE 4-CAMERA VISION SYSTEM The PPT IMPACT M-Series embedded vision system has 4 independently operating cameras, each running its own inspection/ guidance program, at different times or simultaneously. The M-Series embedded M40 processor eliminates the need for a separate computer for programming and operation; it utilizes PPT VISION’s universal IMPACT software, which works with the Microsoft Windows XP operating system and features direct connections to a monitor, keyboard and mouse. PPT VISION; 952-996-9500; www.pptvision.com

Designed for contamination-sensitive food industry applications where frequent disassembly and cleaning are required, the K-Tron Premier Quick-Clean Aerolock rotary valve can be disassembled and cleaned by one person using a hand-held wrench, without disengaging it from the system or disturbing the seals or bearings. Available in 5 sizes from 6 to 14 in. and capable of handling pressure differentials to 0.8 bar (12psi), the valve comes standard with a 10-blade stainless steel rotor that is equipped with relieved tips to prevent material build-up on the housing. An optional support carriage facilitates removal of the rotor. K-Tron; www.ktron.com

INNOVATIVE SOLUTIONS FROM A SINGLE SOURCE Pneumatic Conveying Systems. Smoot has been engineering and designing pneumatic systems for more than 40 years and has supplied simple railcar un-loading systems to large multi-ingredient systems. Dilute Phase Conveying. Efficient and cost-effective means of transferring dry bulk solid material. Dense Phase Conveying. The answer if your material is abrasive or fragile and cannot handle higher velocities.

Experience, Engineering and Equipment in One Neat Package. DILUTE-PHASE PNEUMATIC CONVEYING

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DENSE-PHASE PNEUMATIC CONVEYING

January 2011 | Food Engineering | www.foodengineeringmag.com

www.smootco.com / Toll Free 800.748.7000 See Food Master, p. 116

TECHNOLOGY S O U R C E B O O K

LIFTER/TRANSPORTERS Offering infinite height adjustment (within range) with a 20:1 mechanical advantage, Southworth Dandy Lift lifter/transporters have a multi-grip position handle with sure-grip cushioning and gentle contours, a Qwik-Grip lowering handle with an oversized, open-triangle design and a 180° access foot pedal with a large, open-loop design that allows it to be pumped from different angles at the rear or side of the unit. Southworth Products Corp; 207-878-0700; www.southworthproducts.com

CASE TAPER Designed for large-run case sealing, the EZ-Tek stainless steel BB-2/S top and bottom case taper utilizes pressure-sensitive tape and features self-centering side rails, a rugged bottom belt drive and heavy-duty mast. EZ-Tek Industries; 800-877-5658

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(305) 591-8935 • www.ludeca.com

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FEX04074Mart_2.indd 1

3/8/07 3:09:13 PM

© 2010 Thermo Fisher Scientiﬁc Inc. All rights reserved. Copyrights in and to the Piggy Bank photograph is owned by a third party and licensed for limited use only to Thermo Fisher Scientiﬁc by Punchstock.

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VIBRATORY SCREENERS 1 to 5 screening decks yield up to 5 precise particle sizes from 2 in. (50 mm) to 25 microns. Diameters from 18 to 100 in. (460 to 2540 mm). Batch or continuous, gravity-fed or in-line pneumatic models with rates to 70 tons/h. Numerous options.

CENTRIFUGAL SCREENERS Exclusive 2- and 3-bearing cantilevered shaft designs provide vibration-free operation while allowing rapid removal of components for thorough cleaning and screen changes. Continuous, gravity-fed or in-line pneumatic models.

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The Columbia Model FL1000-SW palletizer with a fully integrated stretch wrapper can simultaneously stack and stretch wrap a variety of package types including cases, trays, totes, film only and display packs. The heavy-duty palletizer performs a wrap cycle after each layer is placed onto the pallet while the next layer of product is being built. It features Category 3-rated electrical safety components including A-B SensaGuard dual circuit safety interlocks and Sick-type 4-light curtains mounted per OSHA guidelines. Layout possibilities include front, rear and side in-feeds, plus the option of pallet dispensing and load discharge on the same side. Columbia Machine, Inc.; 360-694-1501; www.palletizing.com

See Food Master, p. 48

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January 2011 | Food Engineering | www.foodengineeringmag.com

How can we improve security while lowering our costs?

Our remote management services deliver greater security while reducing your capital and operating expenses. As managed services and the Software as a Service model become more prominent, you need an integrator who leverages their people, processes and technology to secure your assets, enhance your ability to focus on your core business and ultimately your customers. Our Remote Security Management services are comprised of a combination of advanced hardware and software, innovative processes and security expertise. Siemens Security operates UL-Listed Central Monitoring Stations with a team of security professionals ready to provide you with services ranging from traditional alarm management to hosted, remote applications. Siemens has the answers to your toughest questions. usa.siemens.com/security

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TECHNOLOGY S O U R C E B O O K

Westfalia Separator® hyvol ®

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Available with an integrated reverseflow check option for the downstream installation of pneumatic valves, Rexroth MH1 pressure regulators are used for the piping of pneumatic valve manifolds. A tapped port allows relief air to be conducted away from food areas. The pressure regulators are also suitable for use with inert gasses and can be fieldconverted to non-relieving function. Bosch Rexroth AG; www.boschrexroth-us.com

INK JET PRINTER The Videojet 1610 continuous ink jet printer can print up to 5 lines of small, high-resolution characters at speeds up to 960 ft./min. Intended for large-output beverage, canning and food production lines, the printer includes IP65 washdown and dust protection with no plant air required. It features a clean-flow print head design that reduces ink buildup. By reading an embedded microchip, the printer identifies whether compatible fluid has been installed to prevent errors in ink types or switching make-up and ink fluids. Videojet Technologies Inc.; 800-8433610; www.videojet.com

To learn more about optimizing efﬁciencies and product quality with Westfalia Separator hyvol separators, call Philip Cunningham at 510-432-4732 or email to [email protected].

Liquids to Value GEA Mechanical Equipment

GEA Westfalia Separator, Inc. 100 Fairway Court · Northvale, NJ 07647 Phone: 201-767-3900 · Fax: 201-767-3416 Toll-Free: 800-722-6622 24-Hour Technical Help: 800-509-9299 www.wsus.com See Food Master, p. 65

1410T

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Whether you are producing dairy products, fats, oils or beverages, depend on Westfalia Separator® hyvol® separators to maximize capacity and simplify maintenance. That’s because our separators blend performance efﬁciency with uncomplicated design. Standard features, like an easy-to-replace ﬂat belt drive and maintenancefree liquid seals, combine with customized options to meet your food processing needs.

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Lubrication Maintenance Software Lubriplate offers a PC based computer software program that puts your entire lubrication and maintenance schedules at your ﬁngertips. This service is based on a complete survey of your entire plant. Contact Dan Moroses (Newark ofﬁce) for details at 973-589-9150.

No-Charge Follow-up Oil / Fluid and Grease Analysis Lubriplate’s Oil/Fluid and Grease Analysis Program is offered at no-charge on all Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO Cleanliness (optional). An interpretation of the results is included along with suggested actions to take.

In Plant User Lubrication Training Programs We offer training programs tailored to ﬁt your needs. These educational training sessions focus on all facets of machinery lubrication and are not a sales presentation. Seminars are graphically presented with overheads and other support material. Available on-site at your facility or in a local conference room. Contact us at 800-733-4755 for more information.

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PGO-FGL Series - Gear Lubricants • Ultra High-Performance, Polyalkylene (PAG)-Based Lubricants. • Designed for use in bevel, helical, planetary and worm type gear reducers operating in the most demanding food manufacturing environments. • Provides superior protection against micropitting, wear and corrosion.

SFGO Ultra Series - Multi-Purpose Fluids • 100% Synthetic, Polyalphaoleﬁn (PAO)-Based, Fluid Lubricants. • Extremely versatile, recommended for air compressors, hydraulic systems, bearings, gearboxes, pumps and chains. • Available in 13 ISO viscosity grades.

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Plant Security

Access Granted

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February 2009 | Food Engineering | www.foodengineeringmag.com

The potential for malicious behavior in food manufacturing is an ongoing issue, but security concerns also extend to workers and the controls that run today’s plants.

` Kevin T. Higgins, Senior Editor

S

ecurity and safety were two sides of the same food-defense coin when the US Congress approved the Public Health Security and Bioterrorism Preparedness and Response Act in June 2002. The nation was groping for ways to respond to possible terrorist threats, and the act outlined the broad parameters of an effective defense plan, including rapid recall of contaminated products. Accidental product contamination emerged as a continuous improvement focus in the ensuing years. Malicious contamination, on the other hand, has become a background concern, in part because of the absence of dramatic, widely publicized events like this year’s Salmonellaand-eggs event. But terrorists are only one security issue. Food manufacturers also must be concerned with the security of their workers and the automation infrastructure that drives production. Security is a multidimensional concern, and companies are taking a holistic approach to it. Both FDA and USDA issued voluntary security guidelines for food processors in 2002, setting the stage for a wave of assessments of the vulnerabilities of the nation’s 158,000 registered food and beverage facilities. Plant managers were encouraged to assess vulnerabilities in outside security, inside security, storage security and shipping and receiving, and then identify cost-effective actions to address them. As with HACCP, a food-defense plan is specific to the plant, and the guidelines do not proscribe specific actions. Most new and many older facilities include security fencing on the perimeter and card readers inside, but if a hog plant on the Plains affords a clear view to Canada, managers are free to forego fencing and deploy limited resources on other safeguards, such as tamper-evident seals on outbound and incoming shipments. The regulators’ goal was to raise awareness, and facility managers can access security checklists and software programs to assess risk.

Three years ago, FDA partnered with the Institute of Food Technologists and Sandia National Laboratories to create a computerized assessment tool called CARVER + Shock, a 100-plus question risk-assessment tool adapted from the US military’s method of evaluating targets’ vulnerabilities. CARVER is an acronym for six attributes: criticality (the impact of an attack), accessibility, recuperability, vulnerability (the ease of an attack), effect (loss of production) and recognizability of the target by a terrorist. The psychological impact of an attack also is addressed. An attack is a reasonable expectation for a military base, but the public would be shocked if an iconic food brand were compromised. In a security-conscious age, video cameras are becoming commonplace in meat and poultry plants. When production started in August 2009 at Keystone Foods’ Gadsden, AL poultry plant, 89 cameras monitored movements inside and outside. Wherever work in process is exposed to the production environment, a camera is trained on it. Food safety and enforcement of hygienic behavior are the justification for the capital cost and monitoring expense of such a system, but security objectives also are served. Mount Kisco, NY-based Arrowsight Inc. couched its “third-party remote video auditing” service in positivereinforcement terms when it entered the food sphere. Plumrose USA installed 25 cameras in its Council Bluffs, IA meat plant in January 2005, becoming Arrowsight’s first food client. Cameras had been used before, but after the novelty wore off, no one reviewed the videotape, the plant’s general manager explained. Food defense as well as safety was emphasized in the Food Safety Modernization Act approved by the 111th Congress. That reinforced the belief by Adam Aronson, Arrowsight’s CEO, that the time was right to adapt his service to more overt security purposes, focusing on raw www.foodengineeringmag.com | Food Engineering | January 2011

71

PLANT SECURITY ` Almost 100 video cameras monitor the interior and exterior of Keystone Foods’ Gadsden, AL poultry facility, though quality assurance, more than biosecurity, drives camera placement in processing areas.

material storage areas, holding rooms for finished goods and other places that a CARVER + Shock assessment would flag as vulnerable to attack. Aronson expects to begin two pilots of the Arrowsight Food Defense solution in the first quarter of 2011, one at a meat plant and the other at a spice company. Security, not positive behavior reinforcement, distinguishes the new service. Hardware is pro-

vided by ADT Security Services, which augments cameras with motion sensors and RFID card readers to better monitor both authorized and unauthorized visitors to high-risk areas. Unauthorized entry triggers an immediate alert to plant management and remote monitoring of the individual’s movements. Authorized personnel, including sanitation crews, are not necessarily subject to video surveillance unless they approach or handle any sensitive materials. “The facilities in general are very good at ensuring that the wrong people don’t get in the place,” says Aronson, “but once they’re in the plant, there is very little control.” Checkpoints and other restrictions on workflow would be impractical, making passive monitoring a realistic option. Just as cameras ensure compliance with standard operating procedures, remote monitoring with cameras, sensors and card readers can constrain acts of sabotage. “Most workers would be unlikely to commit an act of tampering under these conditions,” he says.

Workplace stress and lost productivity By early September, the year 2010 was well established as another bloody year in the American workplace. The second shooting rampage in six weeks involving a food or beverage facility occurred September 9 when a suspended Kraft Foods worker drove through a security gate soon after being escorted from a Philadelphia biscuit and cracker plant and shot three fellow workers, two fatally, before being taken into custody. In early August, a fired worker at a Manchester, CT beer distributorship fatally shot eight before taking his own life. Workplace shootings killed 421 US workers in 2008, according to the US Bureau of Labor Statistics. Throw in those killed by knives, heavy equipment and the closest available blunt instrument, and the toll climbed to 526, about 10 percent of work fatalities. The mayhem isn’t limited to homicides, of course, with beatings, bullying and verbal berating also disturbing the workforce and diverting attention from the job at hand. Deploying metal detectors to plant entrances might mitigate the most sensational incidents, but that would only treat a symptom. Maintaining workplace tranquility is the goal, and pre-employment screening is the first step in achieving it, according to Park Dietz, president and founder of Threat Assessment Group Inc., Newport Beach, CA. But unless

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supervisors and other managers are trained to detect warning signs and act on staff complaints, psychological profiles are of little use. “Supervisors who look the other way or feel uncomfortable about taking action against a problem worker end up undermining confidence in workplace violence-prevention programs,” says Dietz. “If you want workers to have a safe environment, people need to be comfortable reporting incidents.” At least one in 20 women subjected to domestic abuse also is harassed by her abuser at work, and the effects are felt by at least three of her coworkers. “The impact of that alone is quite disruptive,” Dietz observes. “When you add all the other problems, the costs to production begin to look astronomical.” Workplace homicides numbered about 1,200 a year when OSHA began tracking them in 1984, and a decade later they had leveled off at 800. “But that is such a miniscule part of the overall problem,” Dietz says. Instead of focusing on homicide prevention, he advises food companies to confront workplace security issues such as aggravated assaults (up to 2 million per year) and the more than 10 million incidents of bullying, harassment and verbal threats.

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PLANT SECURITY

` Hand scanners and other biometric devices have found limited acceptance in food and beverage plants, where RFID cards provide an industrially hardened option for controlling worker and visitor access. Source: Ingersoll Rand Security Technologies.

74

It’s in the cards Proximity cards are used in many plants to control entranceways and restrict access to sensitive areas, though the early 125 kHz cards with 26-bit encryption are going the way of the time clock. Smart cards with multiple applications and 128-bit encryption for sensitive information are available for a small premium, and they can be upgraded for advanced security while coexisting with more basic systems. “It’s simply too easy for unauthorized people to duplicate and use another person’s proximity card,” laments Raj Venkat, a marketing vice president with Ingersoll Rand Security Technologies, Carmel, IN. With smart cards like the recently introduced aptiQ card from Schlage, “the workforce is effectively managed” and multiple levels of security and functionality can be delivered, he says. aptiQ readers also can process simple proximity cards and can be integrated with biometric systems, such as hand readers. Two-way, secure RFID communication is one enhancement provided by smart cards. Others are the audit trail and exception reports that are automatically generated. Smart cards also can be used

January 2011 | Food Engineering | www.foodengineeringmag.com

to debit or credit cafeteria and vending machine transactions. But the ability to hold a biometric template is perhaps the most meaningful security enhancement and one that addresses access control on multiple levels. Biometric readers can be placed at entranceways for the general workforce, eliminating the possibility of “buddy swiping” of absent employees’ cards, while maintaining smart card control for sensitive areas in the plant. “The hand geometry reader is well suited to harsh industrial environments,” says Venkat, and it accommodates “a spectrum of credentials” in the plant. Biometric options such as fingerprint readers are not robust enough to survive in food production, he insists. Not so, maintains Philip Scarfo, vice presidentworldwide sales & marketing at Lumidigm Inc. “For years now, biometrics has had tremendous promise, but the real world performance has been less than satisfactory,” he acknowledges. Read-error rates of 20 percent dogged fingerprint systems, with dirty, moist and even excessively dry fingertips defeating the readers. Complete contact with the sensor is necessary for systems based on total internal reflectance (TIR). Lumidigm’s technology, on the other hand, is based on multiple spectrums of light and advanced polarization techniques to model both the surface and subsurface of the skin. Read errors are less than 1 percent, Scarfo says, and reliability can be improved by simply profiling more fingers for each person. The Albuquerque, NM company was founded in 2001. Multispectral imaging was conceived as a way to measure glucose on skin. It proved a poor fit, but researchers observed that light waves in the red spectrum penetrated below the surface of the skin. “If you shine a flashlight with a red emitter, you can see the penetration,” says Scarfo. Lumidigm reinvented itself as a biometric technology firm in mid-decade and is in preliminary discussions with food manufacturers, after successfully deploying systems overseas. More than 400,000 people a day pass through multispectral imaging sensors at the Hong Kong border crossing. Dispensing drugs to nursing home patients is fraught with risk, given the need for positive patient identification to ensure the correct medications are being administered. A San Diego-based medical supply firm called CareFusion tried fingerprint recognition in a system installed in Asia, but TIR readers were not picking up the patients’ prints. Multispectral imaging proved extremely effective, Scarfo says, and it was accepted by medical professionals who are very averse to security technology. “Security is always a layered approach,” he adds, “and having a non-repudiated way to validate who

Who can handle a security challenge this complex?

With leading-edge technology, Siemens combines knowledge and experience to deliver tailored security solutions. To be your long-term partner, today‘s integrator has to provide more than technology; they have to know your business and risk profile, understand the regulatory environment, compliance issues and how to customize an intelligent, layered security solution. The Integrated Security Solutions (ISS) team at Siemens Security boasts a combined average of 27 years in the security industry. Siemens has the highest level of expertise, access to leadingedge products and the talented resources to execute complex solutions. Our team has all of these in-house and ready to deploy. We have the answers to your toughest questions. usa.siemens.com/integratedsecuritysolutions

Answers for infrastructure.

PLANT SECURITY

` Cameras, motion detectors and video recorders are part of the hardware supporting a new plant security system built around the risk assessment tool CARVER Shock, a food industry adaptation of the US military’s vulnerability methodology that FDA and USDA modified to include the psychological impacts of an attack. Source: Arrowsight Inc.

performed an operation is increasingly important in creating an audit trail. This technology makes security more of a guardrail, rather than a barrier.” Pepperl+Fuchs’ Tim Cicerchi will reserve judgment on the ruggedness of biometric readers until he sees one withstand high-pressure washdown. RFID readers are “hardened industrial scanners,” the manager of industrial bus & ID systems says, and they may be the only solution for an access control system that protects critical machinery. Routine maintenance and simple repairs are being pushed down to the operator level at many plants, blurring the line between those workers and maintenance professionals. To limit access to sensitive components that could take a machine down, Cicerchi advocates installation of RFID systems that also record the person’s name, time of access and total downtime. Such applications already exist in automotive and specialized material handling, and the focus on overall equipment efficiency makes machine security an issue in food and beverage, according to Cicerchi, who is based at the firm’s Twinsburg, OH headquarters. Stuxnet in the house Guns, guards and gates always will be central to security, particularly when the objective is to prevent acts of mayhem. Radicals and malcontents are

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not the only security concerns, however. Criminals and industrial spies also must be held in check, and the tools of bioterrorism security aren’t particularly effective. Armored cars still transport large caches of cash, but that is the economy’s pocket change. The financial services industry is on edge about computer-based theft, making risk analysis and risk management a daily priority. Large food companies also must guard against complacency and probe for weaknesses in their automation networks, advises security expert Eric Byres. A process engineer, Byres developed a firewall for OPC-based industrial automation systems while heading a British Columbia, Canada research lab. Marketed as Tofino, Byres’s firewall exemplifies the cyber gatekeepers that isolate a manufacturing automation network from other data connections, including a manufacturer’s business systems. It’s an essential element of a defense in-depth approach to computer security, though the level of protection depends on how well users understand their own network. Recalling an evaluation he performed of a petroleum plant’s industrial automation, Byres says, “I found 17 points of inter-connectivity. They thought they had one.” The Stuxnet worm provides a dramatic example of network vulnerability. Studies by the security software firm Symantec Corp. determined the worm infected Siemens S7 and STEP7 PLCs and WinCC HMI software, but the ultimate target was Vacon and Fararo Paya drives. This hardware configuration runs the uranium enrichment centrifuges used by the Islamic Republic of Iran in its nuclear armaments program. In November, Iranian President Mahmoud Ahmadinejad acknowledged the Stuxnet attack succeeded: By seizing control of the drives, the worm was able to oscillate the VFDs from 2 Hz to 1,000 Hz, eventually causing the equipment to disintegrate. Stuxnet had a specific target, “but like all attacks, there is collateral damage along the way,” points out Byres, chief technology officer at Vancouver Island, BC-based Byres Security Inc. “We know of other sites in North America that had equipment controlled by Siemens PLCs that were reconfigured by Stuxnet, probably by accident. No real damage, but a lot of labor changes and shutdowns.” A USB flash drive is believed to be the Trojan Horse that brought Stuxnet into Iran’s nuclear facilities. An infected USB stick handed out at a trade show could have brought Stuxnet into North American plants, he speculates. Regardless, no defense is foolproof, and cyber attacks are on the rise. Many of them are catalogued by the Repository for Industrial Security Incidents, a Philadelphia area organization

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PLANT SECURITY ` Lock boxes and access control to shipping and receiving areas are fundamental elements of a fooddefense plan, along with driver sign-in and access, and refusal to accept unscheduled deliveries.

that includes ConAgra Foods in its membership, along with automation suppliers and electronics manufacturers. Undisclosed attacks on members are chronicled, along with well-known events, such as the Zotob worm that briefly shut down 13 US Daim-

ler Chrysler plants in 2005, resulting in estimated losses of $14 million. Virtual private networks, isolation zones within the automation network to minimize an attack’s impact, read-only command protocols: Useful tools all, says Byres, but computer security is multi-dimensional. “The average plant is facing criminals or highly motivated special-interest actors,” he says. “There are very few kids left in the hacking business.” RFPs for viruses and worms are posted on shadowy sites, with hired-gun hackers providing Stuxnet-like solutions to criminals and industrial spies. People are a more likely target than products or plant technology. The Bioterrorism Act casts workers as suspects. In reality, they often are victims of harassment or worse (see related story on page 72). Productivity suffers, with absenteeism and turnover compounding the effects of on-the-job stress. The remedies are well known, says forensic psychiatrist

See Food Master, p. 49

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January 2011 | Food Engineering | www.foodengineeringmag.com

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Park Dietz, but food production “is an industry that’s falling behind in using them, and it wasn’t always that way.” Dietz traces his involvement in consumer packaged goods to the 1984 Tylenol poisonings. He assisted the FBI in profiling suspects in product tampering cases, crimes that involved about 3,500

mostly food and pharmaceutical items a year at their peak. In every case where a suspect was identified, the individual had been involved in prior violent incidents. The same pattern existed with workplace violence. Dietz founded Threat Assessment Group Inc., Newport Beach, CA to help employers weed out violent job

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applicants and, if they are on staff, minimize their impact. Proper pre-employment screening can secure the workplace, though effective screening services are few and far between. In-house verification of an applicant’s last employer and where he or she last attended school often reveals “an alarming rate of liars and criminals, in the order of a 10-20 percent hit rate,” he says. That element knows when a company conducts even cursory background checks and will quickly gravitate to employers who don’t, says Dietz. Stress can cause previously stable individuals to become aggressive and even violent, and plant managers and line supervisors need training in what to look for and how to react. To ignore violent behavior is to condone it. Given the proper tools, supervisors begin to hear “hair-raising stories of what has been tolerated,” Dietz adds. “There isn’t a business that couldn’t save money and improve productivity by learning to manage aggressive acts well.” Employee well-being and network security are not addressed in the Bioterrorism Act or the Food Safety Modernization Act, though securing people and data systems requires the same proactive approach as securing the food supply. Under the Modernization Act, “People are going to be personally and criminally liable if they do not address security issues brought to their attention,” suggests Arrowsight’s Aronson. Penalties for ignoring nonproduct security issues don’t include jail time, but the consequences for an organization can be dire. ❖ For more information: Adam Aronson, Arrowsight Inc., 866-261-5656 Eric Byres, Byres Security Inc., 250-390-1333, [email protected] Jim Brooks, Control Risk Group, 213-996-7560 Raj Venkat, Ingersoll Rand Security Technologies, 317-810-3074, [email protected] Philip Scarfo, Lumidigm Inc., 505-730-4949,

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AUTOMATED DATA COLLECTION ` Government inspectors will be a more common presence in food and beverage facilities, adding to growing pressure for manufacturers to quickly document compliance to their HACCP and other food safety programs. Source: Northwest Analytical Inc.

Rapid reporting on demand Tablet PCs, PDAs and even Kindles are replacing clipboards for manufacturers migrating to automated data collection systems for quality control, including HACCP checkpoints. ` Kevin T. Higgins, Senior Editor

M

ore yawns than yelps greeted the provision in the 2010 Food Safety Reform Act requiring all food and beverage manufacturers to have a hazard analysis critical control points (HACCP) plan in place. True, only meat and poultry processors and juice manufacturers were required by USDA and FDA to develop and implement HACCP plans at their facilities prior to the US Senate’s late-November approval of Sen-

ate Bill 510. In reality, the vast majority of US food and beverage manufacturers already have adopted HACCP: Research by the Aberdeen Group suggests 94 percent of production facilities have adopted HACCP. It is a prerequisite to doing business with major retailers and foodservice companies, and third-party audit standards under the Global Food Safety Initiative (GFSI) umbrella heighten the onus on manufacturers to have a food safety system that includes HACCP and documents the corrective actions taken when infractions occur.

www.foodengineeringmag.com | Food Engineering | January 2011

83

AUTOMATED DATA COLLECTION ` Control charts developed by ground beef suppliers to the Agricultural Marketing Service’s school-lunch program use coliform counts as a quality indicator for raw materials. The information complements HACCP and other food safety data gathering. Source: Northwest Analytical Inc.

A clipboard culture characterizes quality control, however, and a small mountain of checklists quickly builds up to document HACCP compliance. Two-thirds of the companies polled by Aberdeen indicated they rely on paper records, consistent with the 64 percent of Food Engineering readers who still use paper logs, according to the 2010 State of Manufacturing survey. Though the remaining third have adopted electronic records, often those records are little more than spreadsheets. Automation experts insist those systems fall well short of the data collection and historian systems that can produce reports on demand to validate HACCP activity. One manufacturer’s finished goods often are another company’s raw materials, and the industry’s interdependency has been highlighted in several recalls in recent years. Melamine contamination in Chinese milk powder

became a global problem in 2008. Confectioners in Europe and elsewhere suffered the most from the melamine recall, though North America was not so lucky in 2009 when peanut paste tied to Salmonella poisonings was recalled by hundreds of companies and involved thousands of products. “Nobody knew where their ingredients were coming from,” Craig Wilson, head of food safety and quality assurance for Costco Wholesale Corp., told attendees at Food Engineering’s 2010 Food Automation and Manufacturing Conference. As a consequence, “we started to require, as part of HACCP, that ingredients be traceable to a supplier that also has a HACCP plan.” “Ingredient problems are causing the big companies to say, ‘We really need to get our arms around this,’” agrees Andrew Kennedy, president of FoodLogiQ, a Durham, NC supplier of quality management software. Unfortunately, complete product genealogies remain more goal than reality. “It’s like sex in high school: Everyone thinks everyone else is doing it, and the few who are doing it aren’t doing it very well,” Kennedy puckishly summarizes. While food safety regulations and self-policing programs are careful to avoid prescribing solutions like automated data

Traceability initiative mines quality data No crisis should go to waste, politico Rahm Emanuel famously observed. The fresh produce segment took that advice to heart in the wake of the 2006 spinach recall and now is rolling out a model program to trace fruits and vegetables throughout the supply chain and maintain a genealogy of products. About 2,000 distinct produce items are packed and shipped to retailers and foodservice distributors in North America, with as many as six intermediaries handling each of the 6 billion cases and cartons distributed each year, estimates Ed Treacy, vice president-supply chain efficiencies at the Produce Marketing Association (PMA), Newark, DE. Pathogenic E. coli contaminated spinach from a single California farm in 2006, but the absence of an effective traceability system meant all growers suffered. “The spinach crisis wiped out the category for months,” recalls Treacy. “Four years later, spinach consumption is just coming back to where it was.” The crisis of confidence kick-started the Produce Traceability Initiative (PTI), a collaboration spearheaded by PMA, United Fresh and the Canadian Produce Marketing Association. A Salmonella outbreak attributed to tomatoes in 2008 coalesced support for the initiative, and a road map of best

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practices was established the following year. By the end of 2011, the trade groups’ members—suppliers of the vast majority of produce—are expected to be attaching 14-digit GTIN codes to every shipping case, and intermediaries will scan those codes as the cases move through the chain. The codes identify the packer and lot number, tying items to the picking date, the source field, the pick crew and data such as chemicals applied and seed source. Most major grocers and the top foodservice distributors, along with FDA, support PTI, notes Treacy, and some have signaled they will make case coding a condition of doing business. In the meantime, early adopters are “reengineering their businesses” and reaping unexpected benefits: Two major growers have narrowed the scope of recalls significantly, and others are driving out costs and boosting productivity. Another is gaining new insight to crew performance, tying both total output and retailer reject rates to specific workers’ daily performance. Yet another is saving more than $400,000 a year because the code reveals whether the produce came from Mexico or the US, eliminating the need for separate country-of-origin cartons for produce moving north of the border.

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AUTOMATED DATA COLLECTION management, software vendors believe both the Modernization Act and GFSI-sanctioned audit programs will give food manufacturers a strong shove in that direction. In S. 510, the term HACCP doesn’t even appear. “Preventive controls” is its stand-in, and the term appears in Section 103, the bill’s key provision, according to Nikki Willett, vice president-product marketing & regulatory affairs at Tampa, FL-based Pilgrim Software Inc. The section specifies “science-based minimum standards for conducting a hazard analysis, documenting hazards, implementing preventive controls, and documenting such implementation.” Satisfying those requirements makes constant revisions and updates necessary as part of a comprehensive food safety management system. Similar requirements exist in BRC, SQF 2000 and other food safety standards under the GFSI umbrella. “It’s not obtaining the GFSI certification that’s difficult; it’s maintaining that certification,” Willett points out. Major companies are concluding that GFSI necessitates an electronic data management system. “The new requirements

put the food industry at the tipping point,” she says, adding, “we’re getting quite a bit of interest, with big companies especially asking for proposals.” ROI calculations The ability to react quickly to a third-party auditor or a public health inspector is important, but software suppliers typically promote other value propositions to manufacturers. HACCP management and quality systems are a tough sell, so automation firms often pitch inventory management improvements, waste reduction through statistical process control (SPC), better weight control and other benefits of automated data collection, storage and retrieval. Many in the software community thought the traceability requirements in the 2002 Bioterrorism Act would drive adoption of data management systems by food companies. That did not occur. Neither did follow-up regulations, such as FDA 306, which was established six years ago requiring manufacturers to produce in-depth, detailed shipping and receiving informa-

Providers of HACCP management software Records management is the Achilles heel of HACCP programs, and the documentation required by more rigorous third-party plant audits is aggravating the situation. The ability to quickly retrieve records of events and the corrective actions taken saves time and money when the auditor is on site, and that is one of the most compelling arguments for software solutions. Food Engineering’s Essential Guide to Manufacturing Software provides a starting point for evaluating and selecting potential solutions. Software providers and their websites include: APEX Software Development Batchmetrics CAT Squared CSB System International FoodLogiQ GE Intelligent Platforms Hertzler Systems IFS North America Itelligence Norback, Ley & Associates Northwest Analytical Oracle Parsec Automation Pilgrim Software Plex Systems ProcessPro Software Rockwell Automation Sage North America Schneider Electric Technology Group International

www.apexsoftdev.com/www.factorywidgets.com www.initechinfo.com www.catsquared.com www.csb.com www.foodlogiq.com www.ge-ip.com www.hertzler.com www.ifsworld.com www.itelligencegroup.com www.norbackley.com www.nwasoft.com www.oracle.com www.parsec-corp.com www.pilgrimsoftware.com www.plex.com www.processproerp.com discover.rockwellautomation.com/information www.sagenorthamerica.com www.schneider-electric.us www.tgiltd.com

The guide presents 24 categories of software, and vendors select the categories that apply to their solutions. Of the 20 firms listed above, two limited their areas of expertise to “HACCP and/or HACCP Management,” while others claimed software solutions in up to 21 categories.

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AUTOMATED DATA COLLECTION ` KPI dashboards on the shop floor are proving to be popular performance-improvement tools in food and beverage plants, like Starbuck’s Sandy Run, SC roasting facility. By displaying quality data as well as productivity metrics, personnel can respond to variances before they become safety issues.

tion within 24 hours. Better inventory management, on the other hand, has a clear ROI, and some software vendors began emphasizing that benefit.

“No one was too interested in FDA 306, and up until a few years ago, I couldn’t get anyone in the food industry to talk to me about traceability,” says David Miller, who heads Operations Technologies, a Greenville, SC software-as-a-service provider focused on supply chain control and compliance. “Even today, maybe 10 percent speak to us first about traceability; the rest are interested in inventory management. But if you automate collection of inventory, quality and HACCP data, there are some hidden jewels in the math.” Unfortunately, jewels often go unpolished. Miller has worked with manufacturers that have data historians that continuously receive temperature readings from thermocouples and write them to a database, yet people continue to copy temperature readings on paper logs for HACCP purposes. “If they utilized electronic HACCP,” he says, “not only would they not have to go out on the floor, a supervisor could touch a button on his Kindle, confirm the temperature and, if it’s not right, be instructed what to do.” Improved weight control often brings manufacturers to Hertzler Systems Inc., Goshen, IN, and real-time capture of this

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AUTOMATED DATA COLLECTION quality data has helped companies such as Hormel Foods save seven figures on a single line by reducing product giveaway. A positive experience with SPC for weight control often opens the door to more automatic data collection, according to Evan Miller, Hertzler’s president, “but the cost justification is coming from the material savings side.” The key is shifting from data snapshots of a process to automated tracking and alarming of individuals who can take corrective action immediately, not an hour or day later. Sharing performance statistics with workers through data dashboards mounted prominently on the production floor is becoming commonplace. “Operators like to know where they stand on an hour by hour basis,” Hertzler’s Miller says. “It helps them act quickly when something is an issue.” SPC has been the focus for Northwest Analytical Inc. (NWA) since its inception in the mid-1990s. Process monitoring and alerting is a core function of the Portland, OR firm’s system, but the industry’s concern with food safety and better quality management has caused NWA to expand its scope. In 2009, NWA added a quality information module to its automation solution to support reporting for HACCP, SOPs and prerequisite programs. “There are always overlaps with MES and other systems,” acknowledges Jeff Cawley, NWA’s vice president-market development, “and all the data must be readily retrievable” when auditors and government

inspectors come to call. “Where we excel is in creating a centralized, organized database that is simpler to use for analysis and reporting.” Whether the data relate to OEE, KPIs, process set points or metal detector events is irrelevant. “People need a systematic way to handle the data, do the analytics and present it in a systematic way that mimics existing paperwork or provides an advanced presentation,” says Cawley. Product family tree Quality management and HACCP compliance extend beyond the four walls of a manufacturer’s plant. A genealogical record of raw materials from the farm to the production process also is needed, and commodity suppliers are addressing that need (see related story on page 84). Those companies must build automated quality systems virtually from scratch. “Small farmers’ biggest investment in technology is a fax machine,” says Ed Treacy, vice president-supply chain efficiencies at the Produce Marketing Association, one of the commodity groups helping to build a technology infrastructure to support a raw materials genealogy. The food industry is following the path blazed in life sciences, where material suppliers not only must comply with safety and quality requirements, they must verify their suppliers are in compliance as a condition of doing business.

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January 2011 | Food Engineering | www.foodengineeringmag.com

AUTOMATED DATA COLLECTION “Brand owners understand that the real issue is managing the thousands of ingredients and materials from hundreds of suppliers,” says Sean Robinson, food & beverage industry manager for GE Intelligent Platforms, Charlottesville, VA. Those companies want their suppliers to document where their materials came from and what was done to them, but they also recognize the need to better document their own workflow, he says. Workflow management also is emphasized by Rockwell Automation Inc. Michael Gay, who oversees the Milwaukee firm’s MES solution, describes his software as “a workflow engine,” prompting operators to conduct tests, record results and alarm supervisors when corrective action/preventive action is warranted. “We focus on the manual testing process,” Gay allows, but integration with automated SPC systems is seamless. The gaps between MES and quality systems can lead to a data quagmire, Robinson warns. Challenged by an auditor to account for HACCP-related information for a single day’s production, one manufacturer spent six days and required 70 people to retrieve supporting paperwork. “We can isolate the data in less than an hour,” he states. While HACCP management is an adjunct to the process management focus of MES, HACCP is the primary focus of other systems. An example is TrackWise, billed as audit man-

agement software by Sparta Systems, Holmdel, NJ. HACCP plans are subject to continuous changes and updates, Sparta’s Katie Dowling, senior solutions consultant, notes. “We manage the process of changing that document.” Software to guide development of a HACCP plan also exists, including a how-to system devised in 1994 with the objective of converting standard classroom methods into a software tool. Norback Ley & Associates calls it doHACCP, a step-by-step approach to identifying crosscontamination risks, establishing CCPs and developing a reliable methodology. It is part of a suite of HACCP software written by John Norback, a mathematician and professor emeritus at the University of Wisconsin. Small USDA-inspected food companies are the primary audience, though many large manufacturers and trade groups have used the reference tools, according to Kathy Ley, coowner of the Middleton, WI firm. “There are HACCP consultants who still use manual methods, crunching out the forms in word processing and then losing data as it moves from form to form,” Ley says. “We see it as an education-planning-implementationmaintenance problem.” “Software in and of itself is not a solution,” notes Eddy Azad, CEO of Brea, CA-based Parsec Automation Corp. “Some data collection can be automated; some has to be facil-

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itated by people. Regardless of how it is collected, an effective HACCP solution must be well architectured and archived. It isn’t a trivial matter, and there will be costs involved.” That statement would have been a deal killer in years past but no longer. The expense of recalls, the resulting damage to a company’s image and the negative impact on public perceptions of the safety of the food supply coalesced industry support for more stringent food safety management systems, particularly among the largest food companies. Opposition to the Food Safety Modernization Act was almost nonexistent: Except for complaints primarily from the produce sector over the exemption of suppliers with limited geographic distribution and revenues of less than $500,000, the legislation was supported by 73 senators in a chamber where even nuclear arms control meets resistance. Insurance underwriters also are paying closer attention to the interlinking relationships between food companies and their exposure to the actions of their clients’ suppliers, adds Operations Technology’s Miller. “For the first time, they are interested in traceability,” he says. Even without the Modernization Act, food manufacturers will face more demanding reviews of their food safety programs. Speaking at the Institute of Food Technologists’ annual conference, attorney Joseph Levitt, former director of the FDA’s Center for Food Safety and Applied

Nutrition, noted key changes in the legislation would be imposed administratively if necessary, including mandatory access to manufacturers’ HACCP records. “This is a very big deal,” Levitt said, and the changes are consistent with industry-supported efforts to crack down on weak links in the supply chain. Hard-dollar return has been the litmus test for automation investments, which made electronic recordkeeping a tough sell. With rapid reporting becoming a condition of doing business, automated capture and storage of HACCP records are being viewed in a new light. ❖ For more information: Andrew Kennedy, FoodLogiQ, 919-484-4400, [email protected] Sean Robinson, GE Intelligent Platforms, 434-978-5000, [email protected] Evan Miller, Hertzler Systems Inc., 574-533-0571 Kathleen Ley, Norback, Ley & Associates, [email protected] Jeffrey Cawley, Northwest Analytical Inc., 503-224-7727, [email protected] Eddy Azad, Parsec Automation Corp., 714-996-5302, [email protected] Nikki Willett, Pilgrim Software Inc., 813-915-1663, [email protected] David Miller, Operations Technologies, 864-787-3971 Mike Gay, Rockwell Automation, 414-382-2000 Katie Dowling, Sparta Systems, 732-203-0400

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POULTRY PROCESSING ` Fomaco injectors from Reiser are used for marinating, curing and tenderizing applications in the poultry industry as well as meat and seafood. Source: Reiser.

Tender birds, tougher challenges Despite improvements in technology, poultry processors are taking it on the chin with environmental issues and the rising costs of water and energy. ` Wayne Labs, Senior Technical Editor

P

oultry processors are up against it. Today, they face issues with water availability, wastewater treatment costs, increasing energy prices, worker safety, food safety and supply chain demands. Grain and commodity prices are up, retailers demand even higher quality, and the industry seems glutted with product. In addition to these challenges, being “green” and maintaining a good public image determine how well a brand is perceived by consumers Not in my backyard! This month, Sanderson Farms opens its new plant in Kinston, NC, initially employing about 400 people, and increasing to 1,500 when it’s in full operation, according to Mike Cockrell, treasurer

and chief financial officer. The project has been warmly received, and according to townspeople interviewed by local news sources, Sanderson Farms is a good corporate citizen and doesn’t cut corners to be a responsible environmental steward. Sanderson Farms had been considering building a second North Carolina location near Wilson, NC. While neighboring Nash County was strongly receptive of a new facility, Wilson was not. Water and environmental concerns, which involved locating wastewater spray fields within a North Carolina Department of Environment and Natural Resources (NCDENR) protected area, nixed the site location. Cockrell says the North Carolina Rural Economic Development Center and Sanderson are looking at other potential sites in Nash County that will be compatible with the environment.

www.foodengineeringmag.com | Food Engineering | January 2011

95

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POULTRY PROCESSING

` In this further processing application, Heat and Control’s CEIA THS 21 metal detector checks for both magnetic and non-magnetic metals, and continuously tests and recalibrates to maintain maximum stability and performance. Source: Heat and Control.

What compounds environmental issues for poultry producers/processors are combined pollution sources—dealing with the manure while growing the birds on the farm, and handling the wastewater and offal when processing the birds. In early 2010, eleven Arkansas poultry companies were put on trial for giving millions of tons of chicken litter to local crop farmers for use as fertilizer which allegedly harmed the Illinois watershed shared by Oklahoma and Arkansas as well as Lake Tenkiller, according to an AP report. Besides being rich in nitrogen, chicken litter contains large amounts of phosphorous, which can pollute a watershed when runoff occurs. Perdue remedied the problem of excess chicken litter by building a recycling plant. Called AgriRecycle, the $13 million facility processes surplus poultry litter from Delmarva farms into pasteurized, organic fertilizer products. The company provides free poultry house cleanouts to farm partners with more litter than they can use. The finished product meets the Organic Materials Review Institute (OMRI) certified organic fertilizer specification and the requirements of USDA’s National Organic Program. It’s used in horticulture, landscaping, organic crop rotation and popular lawn-and-garden products. Water: The new oil? A few months ago, a Newsweek feature story on water shortages around the globe and in the US suggested that in the future, water may become as valuable as

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petroleum in certain regions. Not all poultry processors are faced with a shortage of water, but indeed, the cost of wastewater disposal containing high biological oxygen demand (BOD) loads and total suspended solids (TSS) keeps on climbing. Most processors with large facilities have on-site wastewater processing systems to process the water for certain reuse applications and make it clean enough to send to the public water treatment system without incurring fines. If you ever processed a live chicken for dinner, you know the process uses a lot of water and energy to heat the water for scalding and picking, followed by endless rinsing and chilling. It’s not difficult to accept governmental statistics, that in the 1990s, showed on average it took 8 to 17 gallons of water to process a single 4-5 lb. broiler. But both processing equipment suppliers and processors have improved water consumption over the years since. Last year, NCDENR reported average water usage to process a broiler of the same weight at 3.5 to 10 gallons, which makes a big difference when the scale of birds processed is millions per month. In 1999, the North Carolina Cooperative Extension Service estimated for an average of 9 gallons of water used per broiler, the total cost of water and sewer service for chicken processors averaged 3.5¢ per bird, ranging from 1.9¢ to a high of 8.6¢ per chicken. Certainly, costs are higher today. NCDENR offers suggestions to help processors cut water usage and still be within the law during certain stages of processing such as scalding and rinsing, which require continual water replacement. These include: • Use high-pressure, restricted flow hoses with automatic shutoffs to prevent water loss during inactivity; • Move dry materials (such as flour) off floors mechanically with vacuum rather than with water; • Use conveyors to move scrap meat and viscera; and • Recondition chiller overflow water through filtration, ultraviolet radiation and other accepted techniques; USDA requires an overflow of 0.5 gallon per bird.1 Another way of reducing water usage is through the use of air chilling rather than water chilling, which has been used more in Europe and Canada than in the US. For more information, see “Poultry processors uncover new ways to reduce costs,” Food Engineering, January 2009. Getting a handle on water usage Processors must have a plan in place to monitor water usage. “Wayne Farms is constantly looking for

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Hot water reuse case study Current situation

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• Recover high energy cost of hot water overflow from poultry scalder/paw picker processes for reuse

• Regulate scald & picker O/F • Operator PLC controls • Screen and membrane filter • UV pathogen removal • No heat loss in recovery • Paw picker oil recovery • 5 year lease agreement • Annual savings $180,620 • Less than 0.3 year ROI

` In this hot water reuse case study, overflows from scalder and paw picker lines can be recycled, resulting in an annual savings of more than $180,000. Source: American Water Purification Inc.

100

• Unregulated scalder overflow • High TSS and Salmonella • Target 20-40 gpm overflow • 3 scalder systems - 60 gpm • 1 paw picker line - 40 gpm

ways to conserve water consumption and improve water recycling,” says John Flood, general manager and vice president of Wayne Farms’ further processing business unit. “We track the usage of water (production basis) at our processing plants and compare our performance to the industry via AgriStats.” Beyond saving water, Flood is always looking for investments in “energy-creating opportunities,” as he calls them. “For example, we are presently considering a wastewater methane-gas collection process, which can reduce the amount of purchased fossil fuels in the production steam boilers at one of our slaughter production plants.” A large broiler processing plant that handles 250,000 birds per day and pays $2.50 per 1,000 gallons has the opportunity to reduce water cost by $160,000 annually for each gallon per bird reduction in water use. Some processors report water use of less than 3.5 gallons per bird, which reflects water conservation is working. If, however, a processor uses in excess of 5 gallons per bird, it might be time to hire a knowledgeable consultant who can take a closer look at the operation.2 “Additional water and energy savings can be realized with advanced water treatment technologies, [especially in] chiller and scalder applications,” says Dan Gates, CEO of American Water Purification Inc. (AWPI). Poultry evisceration water reuse is another area for potential savings. Typically, screen and chlorination processes are used, and citric acid additives are often used in the chiller, adds Gates. Chiller overflow water recovery systems can be installed with on-site ozone generators. Ozone is generally more effective with bacteria (99.9 percent kill rate) than chlorine,

January 2011 | Food Engineering | www.foodengineeringmag.com

and both FDA and USDA consider it GRAS for food contact; AWPI has been using ozone since 1997. Since Russia has banned the use of chlorine on poultry imports, ozone is a safe alternative, which leaves no residual levels in product as it breaks down into free oxygen after use. Recovering hot water from the scalder and paw picker overflows is another way to save energy, says Gates. There’s no rocket science to such a system, just a recombination of existing technologies that can help producers reduce water and energy costs. System components can be simple: 1. A 0.01 micron ceramic filter system removes total TSS from used scalder water, returning it to the hot water system at 85-95 percent clarity (automated controls handle back flushes when needed). 2. An ultraviolet (UV) antimicrobial treatment kills Salmonella, E. coli, Campylobacter and other pathogens, sanitizing the water to USDA standards. The process doesn’t change pH. 3. Heat energy is recovered in the overflows, returning water to the front end at a usable temperature. Water temperature is automatically regulated for defeathering, and all system trends and events can be recorded for quality assurance and traceability. Systemic ways to save energy related to water While this article so far has focused on defeathering, washing and chilling operations, there are other places to check, too, says James Rauh, Garratt-Callahan Company cooling water product manager. These include water-saving opportunities in the plant utility room for boiler and cooling tower operations as well as waste treatment options. “And proper boiler firing and use of heat recovery equipment can add to potential energy savings,” states Rauh. Some areas that often waste money include leaking pipes and steam traps resulting in loss of water and BTUs of heat energy, says Rauh. Leaks in condensate return systems also waste water and BTUs. Another common problem is improper burner settings that waste fuel and increases energy costs. Improper chemical feed and residual maintenance cause deposits to form which retard heat transfer and result in increased fuel usage in boilers and electrical consumption in compressors and chillers, adds Rauh. Operating cooling equipment below maximum achievable cycles of concentration wastes water, BTUs and chemicals. Failure to perform general housekeeping on cooling towers or evaporative condensers can increase fan motor electrical costs. Accumulations of sludge in the basins and plugging

POULTRY PROCESSING

` Marel’s SensorX inspection system scans for bones. If any are found, it sends the breast and the image to an operator for contaminant removal. The operator then places the breast back onto the line for rechecking. Source: Marel.

of fill material can foul heat transfer surfaces. Lack of a properly applied and maintained microbial control program in cooling equipment can lead to loss of heat transfer with increased electrical costs and potential for equipment damage, says Rauh. Failure to maintain chemical feed and control equipment can result in corrosion or severe fouling of equipment, both of which consume extra energy and eventually may result in production shutdown for cleaning, repair and possibly replacement. And finally, if on-site waste treatment equipment is not operated and treated properly, potentially recoverable water is lost along with opportunities for recycling that wastewater for reuse in the facility. Rauh suggests plant audits by an independent water treatment consulting company will help processors save water, energy and money by identifying issues and problems that need to be resolved. A summary water and energy audit will demonstrate potential savings and calculate the ROI that can be achieved. Avoiding recalls Compared to the US beef and pork industries, the poultry-meat industry fared very well for the first three-quarters of 2010 on the USDA/FSIS recall archive for pathogens. The same is true for FSIS current recalls and alerts list. The archive contains one turkey breast recall at 17.5 lbs. for Listeria; the current list contains two products for Salmonella and one for Listeria. Of the recalls logged (archived and current), several include foreign materials and a few mislabeled products. When it comes to pathogens, poultry-meat processors are very diligent, or the recall numbers wouldn’t be so low. “Since a large portion of our

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business is further processed products (marinated, grill marked, cooked/par fired, custom processes/portion control, etc.), we put all our products on ‘micro hold’ until confirming tests from our quality assurance teams,” says Wayne Farms’ Flood. “We do not release any products until our testing is complete.” Flood’s vertically integrated, “farm-to-fork” approach to production and a very linear, welldefined supply chain help determine and eliminate issues—if any—before they get to the level of recall. Flood is always looking for new and improved process equipment to achieve better throughput, but two other needs are equally important. The equipment must be mechanically easy to maintain, and it must be easy to clean for food safety reasons. Bacteria can’t hide According to Doug Kozenski, Heat and Control sales manager for prepared foods processing systems, “Heat and Control follows AMI Guidelines for sanitation and construction of ovens and fryers. These guidelines further enhance the cleanable design we have for equipment.” The supplier employs full clean-in-place (CIP) systems to ensure all surfaces of the product zone are thoroughly cleaned during the sanitation cycle. If there are any hard-to-access points, these areas will have specially designed or strategically located CIP spray nozzles to ensure they are fully cleaned, according to Kozenski. A couple of summers ago, Maple Leaf Foods of Ontario, Canada had a serious Listeria contamination, resulting in several recalls and a number of deaths. The cause of the contamination was traced to bacteria build-up in a hard-to-reach area of a slicing machine where cleaning was ineffective. “Equipment is being designed with fewer places that can trap debris that leads to bacteria growth,” says Dane Woods, Cantrell general manager sales/ service/engineering. “Also, technology such as electro-polishing is being widely used to inhibit bacteria growth.” Woods says that as a machine builder, his company is seeing more and more chemical companies introducing antimicrobial agents that kill bacteria and lower the pH to introduce a harsh environment for growth. For more information on antimicrobials and equipment integration, see this month’s Tech Update on pages 123-136. Heat and Control’s batter and breading applicators are designed with large clean-out openings. All covers open fully but remain on the machine to pre-

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POULTRY PROCESSING vent damage or loss. Platforms for weighers and conveyors are also built to AMI guidelines, and the framework is constructed to eliminate flat surfaces where debris and moisture can accumulate. Supports raise equipment above the deck surface to facilitate cleaning. According to Kozenski, conveyors are also designed for easy cleaning access, and side guides and covers on incline conveyors pivot open for full cleaning access. The supplier’s FastBack horizontal motion conveyors now feature sloped plastic covers that shed water and seamless pans with large radius corners. “If you look at the design of equipment today versus just five years ago, food safety has been a high-priority consideration,” says Jeff Ray, marketing manager of Marel Food Systems. Equipment design should be simplified wherever possible. For example, there should be no exposed pulleys, gears or belts. For processing equipment like slicers, the use of direct-drive, enclosed stainless steel (SS) motors makes sense, eliminating several places for bacteria to hide and multiply, adds Ray. The use of variable frequency drives and fully automated controls can both save energy and make equipment safer for operators. Applying the same principles to conveyors may not necessarily eliminate the moving belt as a horizontal motion conveyor does, but for belted conveyors, Ray says using direct-drive SS pulley motors solves several cleanliness issues at once. There are no drive belts or chains between the motor and the belt,

and with completely sealed pulley motors, the gearing is internal and protected from washdowns, and provides no place for bacteria to multiply. According to Dan Plante, JBT FoodTech North American sales director, choosing high-end, sophisticated SS alloys in building machines provides better thermal and corrosionresistant properties while making components easier to clean. Conveyor belting is also an important issue in the fight against bacteria. Plante says belts need to work closely with drive mechanisms, freezers and ovens, and the use of shelf-stacking belts makes this integration easier to do. Foreign materials/bones If you add up the entries in FSIS logs, foreign materials (FM) accounted for as many or more recalls in the poultry industry than bacterial contamination. “Metal detection continues to be the standard for contaminant detection in most poultry plants,” says Kevin Jesch, Heat and Control inspection systems product manager. Metal detectors should be able to filter out the product effect for fresh or frozen applications. As with all processing equipment in a poultry plant, metal detector systems should be rated IP69K, which is a high-pressure/high-temperature washdown rating, says Jesch. Any level of water intrusion can result in corrosion of electronic circuit boards, which can impair operation.

See Food Master, p. 48

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POULTRY PROCESSING ` Used in poultry processing applications, the 3N1 central ozone system is designed for water treatment, sanitation and other food processing applications. This system produces up to 1,500 gpm of ozonated water. Capacity can be increased by adding another 1,500 gpm module. Source: Ozone Safe Food Technologies.

A perennial problem for inspection systems is being able to spot bones and cartilage. Beyond the capability of a metal detector, detecting these materials—which are often very soft in a young broiler— can be challenging even for X-ray systems, according to Ray. “We had one processor where we literally found 50,000 bones in one year in its chicken breast line,” he says. He had to build a complete recovery and rework system to solve this problem. Now, when an on-line SensorX X-ray system spots a chicken breast with a remaining bone fragment, the breast is kicked out and sent to a rework operator, along with the electronic image showing where the bone is. The operator finds the bone based on the image, removes it, then throws the breast back on the line, and it is again checked to make sure the operator completely removed the bone, explains Ray. Larger chickens, bigger problems Chickens entering the processing plant have been gradually getting a little bigger for their age. While this may be good from a yield standpoint, it has created new issues. “Larger bird sizes are driving processors to look at different ways to cut products,” says Jan

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POULTRY PROCESSING Gaydos, JBT FoodTech North American marketing director. “We have added capabilities to our portfolio in ways that allow us to give processors the tools they need to utilize bigger raw material.” As more consumers want fully cooked or RTE chicken, the demand for boneless is becoming greater, and that means processors need deboning operations and X-ray systems, says Ray. “I really don’t see many bone-in chicken applications. The 8or 9-piece pack used to be popular,” says Plante, “but then more people want fully cooked chicken and that’s where the trend continues to go. “Many processors have returned to deboning by humans, because of the variability on birds,” adds Plante. “Because of this, we have gone back to our equipment design to help processors deal with breasts that are bigger. That is where our DSI slicer comes in—because it is able to deal with larger birds, and also keeps workers safe.” Worker safety is critical in equipment design and function, says Woods. Automatic deboners require precision, regular maintenance, new parts and upkeep that some processors are not willing to spend the money to support. “Manual deboning still is hard to beat for yields,” concludes Woods. Automation can help save energy, improve product While some in the industry may have concluded automatic deboning machines can’t cut it, there are other places automation can help—producing a consistent product, saving energy

and managing the supply chain. “We have automated our ovens and fryers to a large extent,” says Kozenski. “When using PLC/ PC controls, we automatically control all cook parameters of the oven and/or fryer.” While the cook parameters are not automatically adjusted on the fly based on automated input, they are repeatable through the use of saved recipes, and can be manually adjusted during production, he adds. The perennial problem of the industry—how to check internal doneness is not just an issue with hamburgers. Cooking parameters would ideally be based on product temperature or yield as product exits the oven or fryer, says Kozenski. “Unfortunately there are no reliable methods with which to monitor internal [core] temps or the net yields on the fly. “Recently, we introduced a new manufacturing information platform called Information That Matters,” says Kozenski. It collects KPIs from critical control points in the line and sends them in real time to smart phones and computers. The system helps measure overall equipment effectiveness (OEE) and informs operators and maintenance people of faults and adjustment needs. Suppliers also need to be attentive to new designs that can save energy. Plante says JBT FoodTech has updated designs that reduce water consumption and power usage. One example he cites is an LVS feed system with coils that saves money in power consumption.

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Supply chain unknowns Supply chain issues are hitting processors from every angle. Wayne Farms’ Flood lists a few cost concerns: commodities (grain/feed), labor, competition, amount of product in the marketplace, transportation, etc. According to USDA’s “Chicken and Egg” report, broiler chicks hatched during October 2010 totaled 767 million, up 5 percent from October 2009. Eggs in incubators totaled 618 million on November 1, 2010, up 7 percent from a year earlier. The question that might be asked is: When the market seems already glutted with product and with higher feed costs, why would the industry increase the flock, eroding profit margins? With the passage of the Food Safety Modernization Act, S. 510, giving the FDA more power, how will this play out in industries monitored by USDA? It remains to be seen. “The bill’s requirements for surveillance and traceability will task the FDA with establishing a tracing system for both unprocessed and processed food, increasing our ability to quickly detect potential problems and determine quick, life-saving solutions,” says Brian Cute, vice president of Afilias Discovery Services. “Importantly, interoperable and standards-based traceability services will provide cost-effective solutions for farmers, food producers, processors and retailers alike.” While technology has solved several problems, suppliers should not lose sight of what poultry processors need today— strategic relationships!

“We obviously want equipment that is reliable, durable and has a significant life and associated warranties,” says Wayne Farms’ Flood, “but we also want our equipment suppliers to have longevity. We prefer our vendors to be strategic partners who will support us in continuous improvement initiatives. Our suppliers need to actively and continuously research new technologies to better engineer their equipment and increase its efficiency.” ❖ References: 1

Saravia, et al. (2005). “Economic Analysis of Recycling Chiller Water in Poultry-Processing Plants Using Ultrafiltration Membrane Systems,” Journal of Food Distribution Research, pp 161-166.

2

William C. Merka, Water Conservation in Poultry Processing, Extension Poultry Science Department, The University of Georgia, Athens, GA.

For more information: Dan Gates, American Water Purification, Inc., 316-685-3333 (ext. 104), [email protected] James Rauh, Garratt-Callahan Company, 650-697-5811, [email protected] Doug Kozenski, Heat and Control, 847-226-5392, [email protected] Jeff Ray, Marel Food Systems, 913-888-9110, [email protected] Dan Plante, JBT FoodTech, 419-626-0304, [email protected] Jan Gaydos, JBT FoodTech, 419-626-0304, [email protected] Dane Woods, Cantrell, 770-536-3611, [email protected] Kevin Jesch, Heat and Control, 510-259-0500, [email protected] Brian Cute, Afilias, 215-706-5700, [email protected]

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See Food Master, p. 82 www.foodengineeringmag.com | Food Engineering | January 2011

109

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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 12:30 p.m.

Golf Tournament 3:00 – 5:30 p.m.

Registration 7:00 – 8:30 p.m.

Welcome Reception

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.

Project Economics: Selling Plant Automation Improvements

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

Registration 7:00 – 8:00 a.m.

Continental Breakfast

Moderator: Christopher Miller, Food Industry Consultant and Founder & CEO, Innovation Focus In this interactive session, audience members will collaborate on project cost analysis 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.

8:00 – 8:10 a.m.

Welcome Patrick Young, Publisher, Food Engineering

12:00 – 1:30

Expo and Lunch

8:10 – 8:30 a.m.

12:00 – 4:00 p.m.

Opening Remarks: The State of Food Manufacturing

Expo

Joyce Fassl, Editor in Chief, Food Engineering 1:00 – 4:00 p.m.

Theme for Day One: Continuous Improvement in Challenging Times

Solutions Theater

SOLUTIONS THEATER SCHEDULE 8:30 – 9:15 a.m.

Keynote Address: The Road to Manufacturing Innovation 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 the need for better management of both human and equipment assets.

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 9:00-9:30 a.m. Siemens Industry, Inc. 9:30-10:00 a.m. Solarsoft Business Systems Track B 9:00-9:30 a.m. Adept Technology

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2:00 to 2:30 p.m.

3:00 to 3:45 p.m.

Refreshment Break Stations

Sanitary Design of Equipment: What You Should Know

5:00 – 6:00 p.m.

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).

Expo Reception 6:00 – 8:00 p.m.

Palm Beach Dinner

W Tuesday, April 5

3:45 to 4:30 p.m.

Plant of the Year Award

7:30 a.m. – 1:00 p.m.

Registration

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.

7:30 – 8:30 a.m.

Expo and Breakfast 4:30 to 6:00 p.m.

Plant of the Year Celebration Cocktail Reception

8:00 – 10:00 a.m.

Solutions Theater Dinner: On Your Own 10:30 – 12:00 noon

Educational Tracks on State-of-the-Art Methodologies

W Wednesday, April 6 Monkeiwicz

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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 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 12:00 to 1:00 p.m.

Networking Luncheon Theme: Best Practices in Operations, Safety and Quality 1:00 to 1:45 p.m

Global Manufacturing Innovation From the Merger of Giants 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. 1:45 to 2:30 p.m

Developing a Food Quality Protocol

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The working relationship between engineering/operations departments and the quality team is crucial to addressing not only product consistency and quality, but also food safety. This session will focus on equipment and tools that ensure food quality as well as the human factor in producing safe foods.

Theme: Sustainable Plant and Process Practices 7:00 – 8:00 a.m.

Continental Breakfast 8:15 – 9:00 a.m.

Building and Maintaining Success in Energy Conservation Speaker: Daniel Fonner, Senior Manager, Global Utilities, Heinz North America The enthusiasm for sustainable manufacturing 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, 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 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 to effectively manage your energy usage and costs as well as your greenhouse gas emissions. 11:00 – 11:45 a.m.

Best Practices in Water Conservation and Reuse Serious water shortages and changes in water availability have caused food and beverage processors to rethink water usage, wastewater treatment and reuse procedures. The session will focus on obtaining quality water at reasonable prices, substituting water of lesser quality where possible, and treating and reusing wastewater. 12:00 noon

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PLANT PROFILE ` Louisiana-local flavors are the specialty of the only ice cream processing plant in the state. Photos by Vic Palmisano

Filling Local Demand Flexible new Kleinpeter Farms Dairy ice cream facility mixes up homegrown success. ` Cathy Sivak, Field Editor, Dairy Foods

T

he space-efficient, $5.5 million Kleinpeter Farms Dairy ice cream plant in Baton Rouge, LA fills ice cream cartons and future prospects for the independent, family-owned dairy. Kleinpeter Farms Dairy joined the premium ice cream market in 2008 as the only Louisiana ice cream processor. Diversification of the dairy’s fluid products creates a practical way to use excess cream, broadens the brand’s retail presence and meets consumer demand for locally produced ice cream. The “only ice cream made in Louisiana” niche fit with the Kleinpeter brand’s boutique-nature and consumer research showing support of locally made foods and products, says Jeff Kleinpeter, president. The executive team’s short list of potential growth avenues combined with a chance invite to a Texas ice cream plant auction swiftly led to plant con-

struction. Within five months, the new Kleinpeter Farms Dairy facility was up and running. The first batch christened most of the eager onlookers with splashes of mix, but trial and error had vanilla and chocolate half-gallons headed to market in January 2008. “Things change fast around here. We don’t have to go through layers of red tape to get things done,” Kleinpeter says. When processing space in the original $4 million, 4,000-sq.-ft. facility proved almost immediately inadequate, a two-phase, $1.5 million project added a processing floor and staging area for a 7,500-sq.-ft. total. As part of the dairy’s environmentally friendly and keep-product-cold commitments, the ice cream plant interior walls are insulated with freezer panels, and doors to freezers open into chilled areas to conserve cold air. As the ice cream facility’s volume grows, new capabilities are added. In September, the produc-

www.foodengineeringmag.com | Food Engineering | January 2011

113

PLANT PROFILE ` Dedicated employees such as Assistant Managers Johntel Moore (left) and Mark Tolbert (right) are behind the success of Kleinpeter Farms Dairy operations.

Ice cream offerings have expanded with capabilities. Halfgallon cartons are now joined by pints, 3-ounce sundae cups and 3-gallon institutional sizes: The flavor count has jumped from two to 24. Varieties including Sweet Potato Pie, Homemade Ponchatoula Strawberry and Buttered Pecan are often inspired by Louisiana cuisine and feature locally sourced ingredients. Flavor development is a team effort with leadership from Don Gerald, the ice cream plant manager and a graduate of the Penn State Ice Cream Short Course.

tion floor added 40 feet of conveyors to ease the manual labor of moving filled product to the spiral freezer. In October, the spiral freezer added new decline equipment.

Farm to filler A century of Kleinpeter family wisdom goes into farm and processing operation management. “The best way to see how the dairy farm manager is doing is to look at the cows. The best way to see how the production department is doing is to taste the milk,” Kleinpeter says.

At a glance: Kleinpeter Farms Dairy Location: Baton Rouge, LA Year plant opened: Ice cream, 2008. Fluid milk, 1955. Size: Ice cream, 7,500 sq. ft. Milk, 44,000 sq. ft. Plant additions/renovations: Ice cream, original 4,000 sq. ft. added 3,500-sq.-ft. processing/staging, 2008 and 2009. Fluid milk, original 550-sq.-ft. facility tripled in 1960, doubled again in late 1960s expansion; cooler size doubled in 1973; blow-mold addition, 2,000-sq. ft., 1982, expanded to 6,000 sq. ft. in 2005; vertical addition to refrigerated cooler space, 2005 (expanded volume, increased crate stack height from five to seven, added insulation); air conditioning throughout processing and load-out areas, 2007. Number of employees: 230 total: 95 sales/distribution; 65 processing/ packaging; 10 drivers; 25 transportation/load-out for milk and ice cream; 5 mechanic repair shop; 15 corporate/office; 15 dairy farm operation. Products made: Fluid milk, orange juice, drinks, ice cream, ice cream mix. Branded butter, cottage cheese and dip lines are co-packed. All milk and ice cream is certified rBHG-free. Total processing capacity: Fluid products, four days a week, 75,000 gallons a day. Ice cream, five days a week, 12,000 half gallons a day. Milk receiving: Two bays, three silos (30,000 gallon, 25,000 gallon, 15,000 gallon). Milk source: Kleinpeter’s 750-cow operation, 25 percent; 20 independent dairy farms; balance loads from a cooperative. All milk certified rBGH-free. Pasteurization: 4,000 gallons an hour. Pasteurized storage capacity: Ice cream mix, 15,000 gallons in three tanks (5,000 gallons each). Fluid, 21,000 gallons in five tanks (3,000-7,000 gallons).

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Number of production lines/types: Ice cream, single-head halfgallon filler (25 a minute, also fills pints, 3-ounce cups and 3-gallon sizes). Fluid, five dedicated fillers: 21-head half-gallon, 18-head quart/pints/half-pint bottles, 15-head gallon (40 per minute), halfpint paper, school milk pouch. Spiral freezer: 900 sq. ft., 30-ft. tall; 4,000 half-gallon capacity (-40˚F). Blow-mold operations: 6,000 square feet; three lines produce 7,200 units an hour. Finished product storage: Freezer, 4,000 sq. ft., 300,000 half-gallon capacity (-20°F). Refrigerated, 6,000 sq. ft. (31°F). Fleet: 80 distribution trucks (housed on site and at substations) include nine refrigerated trailers, 20 dry van trailers. Additional five raw milk tankers for on-farm raw milk pickups. Distribution capabilities: Ice cream, 650-sq.-ft.-racking/load-out area, two load-out docks. Fluid, 1,000-sq.-ft.-palletizing/load-out area, six load-out docks. Five refrigerated trailers service substations for route deliveries. Route delivery/sales equipped with stateof-the-art hand-held computers. Wastewater treatment: 80,000-gallon capacity.

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PLANT PROFILE ` The spiral blast freezer handles 4,000 half-gallon cartons at a time.

To protect product integrity and extend overall shelf life, Kleinpeter Farms Dairy takes multiple steps to circumvent the often brutal Louisiana heat. “The heat is a serious concern here,” Kleinpeter says. Efforts start at its dairy farm, where fresh, raw 102˚F milk is run through heat plate exchangers to cool it to 36˚F prior to shipping to the processing campus. The family dairy operation supplies fluid and ice cream operations with roughly 25 percent of its raw rBGH-free milk needs, with the remainder supplied by 20 independent dairy farms and balance loads from a cooperative. The company’s five milk haulers handle transportation from the family farm and other independent producers. Two covered receiving bays at the fluid operation are the site of preliminary load tests. “Our specs for rejecting a load are twice as stringent as the requirements for the state of Louisiana. We really are tough,” says Fluid Plant/Operations Manager Jerry Kleinpeter.

Intake procedures require rBGH-free verification and tests for butterfat percentage, antibiotics, bacteria, somatic cell count, cyroscope readings and temperature. Testing is conducted in the in-house lab under the supervision of Jackie Goudeau, quality assurance director. All raw milk must be 42˚F or less upon arrival. Accepted milk is pre-cooled to 32.5˚F in a glycol heat exchanger prior to storage in three silos, with 70,000-gallon total holding capacity. Milk is then piped into the fluid processing plant, which added air conditioning in 2007 to improve the efficiency of chilled tanks and other equipment. Stainless steel piping is further insulated to keep milk at the coldest temperature possible. Milk enters one of five standardization units with a total capacity of 21,000 gallons; fat content is adjusted according to the fluid plant’s production needs. Milk is homogenized to prevent separation, pas-

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PLANT PROFILE teurized at 171˚F for 15 seconds and then sent through a plate cooler for rapid chilling. Flavoring is added if needed for the day’s fluid production run, and then milk travels to five in-wall holding tanks with a combined 21,000-gallon capacity. Milk is then piped to one of five milk filling machines; plastic containers are formed in the in-house blow-mold operation. Controls for fluid filling operations were upgraded from manual to computer softwarerun in September. The automated data tracking built into the system creates additional operator accountability. Once filled and crated, milk is stored in the refrigerated cooler and held at 32˚F for load-out. Creative concoctions Fluid processing creates ample cream for blending into bases for 38 to 40 percent butterfat ice cream. Simple flavor bases are created in the fluid operation, and then travel to one of three 5,000-gallon ice cream facility storage tanks. The outdoor pipes from the fluid plant to the holding tanks are heavily insulated. Mix is deliberately held in the tanks for one day to help form unique Kleinpeter flavor profiles. “It’s an added touch,” Kleinpeter says. The base mix travels from the tanks to flavor vats and is routed through the inclusion hopper. The variegate sprayer is the last stop before reaching the filler, which has a 25 half-gallon carton

per minute capability. Ice cream production is typically limited to one flavor per day, with 12,000 half-gallon per day capability. The first delivery of bulk ingredients for Bread Pudding showed the occasional challenge in sourcing products from specialty ingredient suppliers unfamiliar with ice cream processing demands. The bread pudding ingredient was delicious, but didn’t initially distribute through the carton properly, impacting final product taste and inclusion appearance. After several tries, Gerald decided the bread pudding mixture was too dense and moist to properly go through the inclusion feeder. The supplier picked up the mixture to revamp it, with success: Bread Pudding rolled out in September along with four other new flavors. Filled cartons are shrink-wrapped in bundles of three to ease mixed pallet load-out. The bundles travel by conveyer to the opening of the adjacent 30-ft. tall, 900-sq.-ft. spiral freezer and are flash frozen at -40˚F. The spiral decline system addition in October makes it “easier and less expensive to get the ice cream from the tip top of the spiral blast freezer to the palletizing area,” Kleinpeter says, noting added reliability and product protection benefits. Product is stored in the 4,000-sq.-ft., -20˚F freezer on an 18-ft. tall racking system accessed via forklift. The freezer currently utilizes 35 percent of 300,000 half-gallon capacity. Prior to distribution, finished products are spot-tested for coliform count, standard plate count, butterfat and taste. Ice cream

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PLANT PROFILE ` Sanitation is a critical component to the Kleinpeter Farms Dairy quality mission.

der based at distribution substations to more efficiently serve expanding delivery areas. Product is loaded straight onto route trucks from trailers at the substations to reduce handling.

approved for release is easily accessed from the drive-through freezer in a 650-sq.-ft. load-out area kept at freezer temperatures to protect product integrity. Ice cream bundles are stacked on pallets or wheeled racks and loaded onto trucks in one of two bays. Extra roof insulation and strip curtains on both ice cream and refrigerated truck doors contain interior temperatures during loading and delivery. Ice cream trucks are held at -10˚F. Colorful art featured on the company’s seven new ice cream trucks reinforces the brand’s image and is being added to the entire fleet at a rate of one trailer per month. Half of the 80-vehicle fleet is housed at the processing campus, with the remain-

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Sustaining operations The plant’s small footprint, made possible by co-location with the fluid plant, conserves energy and reduces the watershed impact. In addition to base mixing and storage in the fluid operation, the ice cream plant utilizes CIP sanitation run through the fluid plant. The processing facility campus houses a non-mandated wastewater treatment plant. It also captures refrigeration process ammonia gas to preheat city water used for boiler water; piping carries the hot gas through the water, reducing the energy needed to heat it. Fluid operations run four days a week, 20 hours a day, while the ice cream plant runs five days a week, 12 hours a day, maximizing shared facility use. Attention to every detail, every day, by every employee, ensures quality products and brand integrity, Kleinpeter says. “I can’t pay them enough to care with the passion they have for our products.” ❖ This article originally appeared in the October 2010 issue of Dairy Foods.

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See Food Master, p. 3

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` Avure’s HPP equipment currently enhances food safety for a vast majority of more than $3 billion of food products sold annually around the globe. Source: Maple Lodge Farms, Ltd.

The heat may be off, but the pressure is on

`

As consumers desire fresher tasting food, the challenge for processors is to produce bacteria-free products while maintaining flavor, color and texture.

D

id you ever notice that the space allotted to canned foods in your supermarket seems small compared to that of fresh, frozen, shelf-stable and RTE foods? Why? With today’s emphasis on fresh and healthy meals, consumers are purchasing fresh, frozen and RTE foods that maintain vitamins and nutrients and seek lower sodium alternatives. Adjusting to this changing market requires some rethinking of processes. We all want food that is safe and delicious, so how can food products be kept fresh and free of bacteria? W hat

options are available with non-thermal processing techniques that are both effective and reasonable in cost? Are there other benefits besides killing residual bacteria? Will consumers accept these new techniques? Not every technology works equally well for each food or beverage, and while some options are more effective than others in killing bacteria, convincing consumers to buy products treated by particular methods may prove to be a challenge. However, there have been some changes in efficacy and consumer acceptance.

www.foodengineeringmag.com | Food Engineering | January 2011

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T E C H U P DAT E

` This chart shows the reduction of E. coli O157:H7 on lean wafers sprayed with various antimicrobials in a Ross tenderizer with integral intervention. There were 14 antimicrobials tested with varying results—not all are yet approved by regulatory agencies. Source: Oklahoma State University/Ross Industries.

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Irradiation thrives When FE investigated some of the non-thermal options open to processors in 2007, it seemed irradiation had lived its last half-life, especially after a cold storage warehouse in Quakertown, PA lost its battle with the local government to set up an irradiation operation. Now, according to Ron Eustice, Minnesota Beef Council executive director, two operations are up and running around the clock to handle hamburger and other products. Sadex Corp. (Sioux City, IA) offers electron beam technology, and Food Technology Services Inc. (Mulberry, FL) provides gamma radiation-based services; a third company in Hawaii uses X-ray on produce. Because irradiation has a high initial cost and requires specialized equipment and knowhow, processors will probably find that irradiation service providers (as the three just named) will be the best solution. With this option, processors send off their pallets, which are irradiated and ready for distribution to retail stores. Though the market for irradiation is still in a nascent stage, the global market is expected to exceed $145 million by 2015, according to a Global Industry Analysts (GIA) report entitled, Food Irradiation Trends: A Global Strategic Business Report. North America and Europe account for a major share of the revenues in the global irradiation market. Growing concerns over food-borne disease outbreaks caused by pathogenic bacteria such as Campylobacter, Salmonella and Trichinae and the need for complying with international standards of quality in an increasingly globalized world are expected to fuel the adoption of irradiation, says

Janaury 2011 | Food Engineering | www.foodengineeringmag.com

the report. Countries looking for alternatives to fumigation, chemicals and other treatment processes are looking toward irradiation as a solution as well. “Thanks to Codex Alimentarius Commission of FAO/WHO [CAC], food irradiation has been cleared for use in any foods using any dose of radiation,” says Venkatarao Potty, chairman of Diversified Food Technologies (Mysore, India). More than 40 countries have adopted food irradiation to a varying extent in different foods, though Brazil and Pakistan are the only two countries totally adopting the CAC guidelines, says Potty. Food wastage, especially in poorer countries, will be a major reason for adopting irradiation. “The irradiation process is one of the cleanest with very low recurring cost, but there is still significant consumer resistance because of the inherent fear of radiation and the hazards associated with it.” While the Center for Food Safety May 2007 Fact Sheet says studies found benzene, toluene and 2-alkylcyclobutanone (2-ACB) in foods after irradiation, there has been confusion about the levels recorded and the validity of the studies. Information from Food Irradiation Processing Alliance (FIPA) says FDA reviewed the data supporting the safety of irradiated foods and concluded there is no adverse effect from eating irradiated foods that may contain 2-ACB in the quantities produced. Likewise, benzene, a known carcinogen, is naturally present in an ordinary egg with levels 1,000 times greater than that in an irradiated hamburger, according to FIPA. When asked who’s using irradiation and if there have been any negatives, Eustice says, “Omaha Steaks and Schwan’s irradiate 100 percent of their raw ground beef items and have done so since 2000. Both companies have seen sales rise; however, the increase is not necessarily due to irradiation. But one can certainly conclude that the fact they sell irradiated product has not been a negative. Wegmans Food Markets proudly offers irradiated fresh-ground beef in chubs and has done so for many years.” The naysayers argue that irradiated food products have an off-taste or color. But if that were true, argues Eustice, Schwan’s, Omaha Steaks and Wegmans would not be marketing the millions of pounds of beef they irradiate. “The issue of taste as far as I’m concerned is a red herring,” he states. On August 22, 2008, FDA published a final rule allowing the use of irradiation to make fresh iceberg lettuce and fresh spinach safer and last longer with-

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See Food Master, p. 63

T E C H U P DAT E

` Sandridge Food installed a high-pressure processing system from NC Hyperbaric to pasteurize foods without any noticeable change to its products’ appearance, taste, texture and nutritional value. The system can extend shelf life beyond 60 days for a variety of products. Source: Sandridge Food.

out spoiling. According to FDA, irradiating these vegetables will help protect consumers from bacteria such as Salmonella and E. coli O157:H7. This final rule came after lettuce and spinach contaminations, largely in San Benito and Monterey Counties in California. In the article, “Wild Pigs in California: The Issues” (Dec. 2007), Marcia Kreith, program analyst at the University of California Agricultural Issues Center, cited wild pigs as one possible source for the produce contamination. Helping to confirm this issue as a problem, Peter Muriana, professor/food microbiology at Oklahoma State University (OSU), points out that pigs captured and tested from the affected areas had the same E. coli species in their feces as the nearby cattle, which were also suspected because of runoff from farms. Muriana suggests that even if a field with crops were fenced off from land animals, an airborne assault would still be possible from flies and/or bird droppings. Other foods approved for decontamination by irradiation in the US include (followed by irradiation level in kGray): pork (1), spices (30), dried vegetable seasonings (30), enzymes (10), herbs (30), fresh or frozen poultry (3), mechanically separated poultry meat (3), fresh (4.5) and frozen (7) red meat, shell eggs (3) and sprouts (8). Fresh vegetables and fruit have also been approved for disinfestations at 1 kGray levels of radiation. The Gray equals the equivalent of 1 joule (1 watt-second) of energy absorbed by 1kg of matter, or 100 rad. Pulsed electric field The use of pulsed electric field (PEF) technology has been tried in some juice applications, but was

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providing inconsistent results. Since then, according to Glenn Hewson, Avure Technologies vice president of global marketing, Genesis Juices has switched from PEF to high-pressure pasteurization because PEF was not providing enough coverage. According to recent FDA information, application of PEF is restricted to food products that can withstand high electric fields, have low electrical conductivity and do not contain or form bubbles. The particle size of the food in both static and flow treatment modes is a limitation. Also, due to the variations in PEF systems, a method to accurately measure treatment delivery is still needed, according to FDA. There is still some interest in PEF in food and beverage processing, but it seems to be a technology looking for a large-scale application. Most recently, a paper entitled, “Design of High Voltage Pulse Generator for Pasteurization by Pulse Electric Field (PEF),” published in the International Journal of Computer and Electrical Engineering, describes a PEF system to be applied for the pasteurization of apple juice. The paper found that to achieve an efficient kill rate, the average voltage and current required were 17 kV and 0.48 mA respectively. Power was applied from 10 s to 60 s, and the electric field strength delivered to the chamber was 0.65 kV/cm.1 Originally covered in a lengthy article entitled “Kinetics of Microbial Inactivation for Alternative Food Processing Technologies—Pulsed Electric Fields,” which can be found on FDA’s website, PEF has found new potential in wastewater treatment. However, the authors of a paper given at the Second Euro-Asian Pulsed Power Conference suggest PEF energy requirements are too great and costly to make it a good choice for most food applications, and suggest processors would still find thermal pasteurization less expensive based on energy requirements. Consequently, the authors suggest PEF is a good technology to apply in conjunction with thermal methods in hospital wastewater treatment.2 High pressure is on The reasons for choosing high-pressure pasteurization are many—even though the entry cost can range from $1 to $2 million depending on the capacity of the unit. But processors can opt to choose a service provider if they can’t justify the initial investment. For those processors that actually want to purchase HPP equipment, adjusting the workflow is often necessary, but may at first seem counterintuitive, says Avure’s Hewson. A processor may assume it needs one HPP unit per line. But it

See Food Master, p. 64

T E C H U P DAT E ` ListShield is an FDA-cleared and EPA-registered nonchemical antimicrobial preparation for controlling Listeria monocytogenes. The active ingredients are naturally occurring bacteriophages that selectively and specifically kill Listeria bacteria. The product can be used directly in food or on food contact surfaces. Source: Intralytix.

makes more sense to stack up finished product from several lines during the course of the day, and then run it through the HPP system, since most of these systems are now designed to operate up to 22 hours a day with some time set aside for cleaning and routine maintenance. Grid Path Solutions is a system integrator and installer/ servicer of NC Hyperbaric Systems (Spain) HPP equipment in Canada and the US. According to Grid Path’s Vice President of Marketing Mike Billig, NC Hyperbaric’s equipment has been

built with redundant system components so it can continue to run while being repaired by the maintenance crew. It’s important to remember that HPP equipment is batch operated, and capacities generally run from 55 l to 420 l. One historical barrier toward a more mainstream implementation of HPP was that batching supported relatively low throughputs, says Francisco Purroy, NC Hyperbaric technical sales manager. But he says this barrier no longer exists with the faster, bigger machines capable of achieving more than 10 cycles per hour and capacities in excess of 2,000kg/hr. (4409 lbs./hr.). NC Hyperbaric also offers a 300 l tandem machine. Both Avure and NC Hyperbaric offer horizontal-loading machines, which makes them easy to load and unload. Depending on the application, hold times under pressure generally range from three to five minutes, with the longer time being needed for drier products such as salami. HPP at 6,000 bar (87,000psi) reduces Listeria by a log of 3.5 and both E. coli and Salmonella by a log of 5. Listeria, a gram-negative bacterium, is

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January 2011 | Food Engineering | www.foodengineeringmag.com

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T E C H U P DAT E harder to kill because its outer coating is more difficult to penetrate than gram-positive bacteria, says Hewson. But with the pressure, the spoilage mechanism bacteria are also killed. Why choose HPP? Consumers have been putting the pressure on retailers for fresh products with a minimum of salt and preservatives, says Hewson. So retailers have pressured processors for food that meets these requirements. Besides HPP’s advantage of killing bacteria, consumers enjoy the extended shelf life of fresh product. For example, a 48-oz. jar of Jack’s Special Medium Salsa purchased at Costco on November 15, 2010 has a “best by” date of December 24, 2010. Made with entirely fresh ingredients, a 2-tablespoon serving has only 140mg of sodium. While extended shelf life is a plus for consumers, processors can take advantage of it as well, says Billig. “This technology allows such a long extension of shelf life that a lot of meat manufacturers don’t give up all that shelf life to the consumer; instead they keep it as internal gains so they can run full shifts, accumulating product, rather than making several short-run changeovers.” This, he says, improves overall efficiency and lowers manufacturing costs. Three years ago, the average cost of HPP processing was approximately 5-10¢ per pound. Billig says the larger-capacity machines available today can allow processors to get the costs down to about 2-3¢ per pound, which includes the labor to run the equipment,

depreciation, utilities and spare parts. Hewson’s estimate is a little more conservative at 2-8¢ per pound, but he reminds processors they can subtract the cost of chemical additives from his estimate. As both Hewson and Billig suggest, many processors are using HPP for reasons such as: touting products as “all natural” with no preservatives, using shelf life to gain precious time and having an extra measure of quality and assurance that their products are safe. While HPP can gray the color of hamburger, it does not change its flavor or texture. But HPP, says Billig, can separate the protein that holds lobster meat to its shell, making it easy to extract 100 percent of the raw lobster meat once the lobster has been run through HPP. Processors that use HPP include Sandridge (bulk deli items), Maple Lodge Farms (High Pressure Protection brand deli meats), Ifantis (Athens, Greece—Freshpress brand deli meats), Ghezzi (Florence, Italy—preserved cod), Fresherized Foods, Calavo, Simplot, Garden Fresh Gourmet and Hormel (Natural Choice meats). The future may be bright for HPP for yet another reason. Diversified Foods Technologies’ Potty suggests that in many parts of the world the cost of traditional thermal processing may eventually become so high that HPP will make sense, not only for all the reasons already covered, but also because HPP uses less energy and, therefore, will cost less to use.

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.

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See Food Master, p. 86

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T E C H U P DAT E Bacteriophages spread EBI Food Safety and Intralytix have developed bacteriophages to combat Listeria, and work is underway to develop phages that can fight E. coli and Salmonella as well. According to Food & Water Watch (FWW), in January 2007, the US Department of Agriculture approved an OmniLytics Company bacteriophage product designed to be sprayed, misted or washed onto cattle hides to reduce the presence of E. coli bacteria. E. coli presents its own problems when it comes to creating a successful bacteriophage. According to Dirk de Meester, EBI Food Safety director of business development, O157:H7 isn’t the only E. coli serotype that is at issue. There are several other dangerous serotypes (e.g., O26, O103, O111 and O145), and tests are only now becoming available for them. Fighting O157 may take up to 60 different phages, and being successful with O157 doesn’t guarantee success with other serotypes. In addition, since E. coli hasn’t been as much of an issue as Listeria and Salmonella in Europe, research on O157 isn’t as critical. De Meester attributes Europe’s fewer E. coli problems to better animal husbandry in the feedlots and stockyards. According to Alexander Sulakvelidze, Intralytix chief scientist, his company has an application pending with FDA for the E. coli-targeted phage preparation called EcoShield, to be used for reducing or eliminating E. coli O157:H7 levels in ground beef. This phage is expected to be available this year. In addi-

tion, Intralytix has developed a phage preparation targeting major pathogenic serotypes of Salmonella. The phage, SalmoShield, is being submitted for regulatory review early this year. It’s important to remember that the use of bacteriophages is an additional measure to a processor’s best hygiene methods, says de Meester. EBI’s product, Listex, will get rid of Listeria, but not other bacteria that might be harmful or will decrease shelf life. “It’s not an excuse to go weak on cleaning,” he adds. How effective is the use of bacteriophages compared to other non-thermal techniques? “Typical reduction of targeted bacterial loads as the result of phage treatment is 95-100 percent,” says Sulakvelidze. “This is comparable to HPP or irradiation. However, there are important differences among these three approaches, including costs.” For example, he says HPP’s use on fresh products (except liquids) can give the appearance of being cooked. Both HPP and irradiation require very large up-front capital expenditures and may cost upwards of 15-30¢ per pound, according to Sulakvelidze. With phage applications, there is no need to purchase equipment, application costs about 2-5¢ per pound, and the treated food’s flavor, appearance and texture are not changed. FWW raised the concern of bacteria developing resistance to phages in the same way they have to antibiotics. According to Sulakvelidze, the emergence of phage-resistant mutants is likely to occur eventually (as happens with other antimicrobial

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See Food Master, p. 56

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T E C H U P DAT E agents); however, that situation has not been reported to negate the efficacy of phage applications thus far. Furthermore, when such mutants do emerge, the bacteriophage preparations can be easily and rapidly upgraded by substituting new phages that have full potency against the resistant mutants (in clear contrast to antibiotics). Such regulatory practice is somewhat unique to bacteriophage products, but FDA’s clearance of the Intralytix ListShield application, which allows the company to maintain that cocktail’s future efficacy by updating it with new phages if necessary, indicates the approach has merit, says Sulakvelidze. According to de Meester, bacteriophages do not lead to resistance, but it may be easier for bacteria to learn resistance where a large population of the bacteria exists. For example, you wouldn’t use a phage to treat a reservoir with fish because the probability of a dominant strain developing in such a large environment would be greater than treating the bacteria on the fish after processing. Surface treatments and other considerations One application that may have more than one solution is the intervention against E. coli for blade-tenderized beef. Currently, the FSIS does not require mechanically tenderized (non-intact) meat products to be identified. Therefore, consumers and retail outlets, such as restaurants, do not know whether the products they have purchased are intact or mechanically tenderized.

OSU’s Peter Muriana has been working with Brad Morgan, professor/meat science at OSU, and Wayne Spillner, an engineer at Ross Industries, to find an appropriate surface treatment that can be applied to steaks before running them through blade-tenderizing equipment. In one sense, the problem is similar to hamburger: If bacteria are on the surface, grinding and mixing meat together or hammering the surface with knives will drive the bacteria through the meat unless it is treated first. Muriana recalls some recent E. coli outbreaks were attributed to blade tenderization of steak. Because most people prefer steaks not well done, killing any E. coli before the knife-tenderization process is vital. Muriana and Morgan, working out of the R.M. Kerr Food & Ag Products Center’s 100,000-sq.-ft. research and food processing facility, examined the application of 14 different antimicrobials provided by 10 chemical suppliers for efficacy. Some of the chemicals included HCl and citric acids, copper sulfate pentahydrate, buffered sulfuric acid, lactic acid, hydrobromic acid and several others and combinations. One particular solution provided a 3.61 log reduction in bacteria, although not all chemicals have been approved by FSIS/USDA. Muriana says the group will also be experimenting with ozonated water and possibly ultraviolet radiation. A problem with ozonated water is its potency can be diminished when using it with organic material. This is also true when using chemical

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Moving science forward

T E C H U P DAT E generators to create hypochlorous acid, especially when the legal concentration that can be used is 50ppm. Ultraviolet light is a line-of-sight intervention, and the ability to penetrate nooks, crannies and bottom surfaces is difficult without a method to turn the meat so it is evenly exposed before the tenderizing operation. Liquid antimicrobials may be sub-

sequently used to exacerbate the injury to bacteria caused by UV light. Muriana has been working with both Unitherm and SanAquel to undertake further testing with hypochlorous acid generators in combination with produce and vegetables, where the legal concentration limit of hypochlorous acid is 200ppm. With less organic con-

tent in vegetables and fruits, the E. coli kill rate using hypochlorous is much more effective than with meats. In addition, vegetables with tough skins like tomatoes, peppers and onions are good candidates for this treatment. Consumers want fresh, tasty and safe products, and non-thermal pasteurization techniques are making it possible to deliver safe food products with longer shelf life that also taste good. Finding the right treatment(s) will take some careful consideration, and chances are more than one treatment may be necessary. Most important, non-thermal pasteurization techniques should be used as part of an all-encompassing food safety quality program—not as an excuse to be sloppy prior to the treatment. In addition, what might seem obvious needs some attention; that is, farms must follow best agricultural practices to help assure their produce and livestock are not delivered to processors laden with excess bacteria that could have been eliminated at the farm. ❖ References: 1

“Design of High Voltage Pulse Generator for Pasteurization by Pulse Electric Field (PEF),” International Journal of Computer and Electrical Engineering, October 2010; Vol. 2, No.5.

2

“Critical Comparison between the Pulsed Electric Field and Thermal Decontamination Methods of Hospital Wastewater,” Gusbeth, Frey, Schwartz, Rieder; Institute for Pulsed Power and Microwave Technology, Forschungszentrum Karlsruhe, Karlsruhe, Germany.

For more information: Francisco Purroy, NC Hyperbaric, 34 947473874, [email protected] Brad Morgan, Oklahoma State University, 405-747-2960, [email protected] Dirk de Meester, EBI Food Safety, 31 (0) 317 421 414, [email protected] Peter Muriana, Oklahoma State University, 405-747-0040, [email protected] Wayne Spillner, Ross Industries, 540-439-3271, [email protected] Ronald Eustice, Minnesota Beef Council, 952-854-6980, [email protected] Alexander Sulakvelidze, Intralytix, 410-625-2533, [email protected] Glenn Hewson, Avure, 800-959-1135, [email protected] Mike Billig, Grid Path Solutions, 905-643-0955, [email protected] Venkatarao Potty, Diversified Food Technologies, [email protected]

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FIELD REPORTS

Produce supplier gains efficiency with MES/weighing system

`

System provides traceability data to help meet government regs and measures operator performance.

P

lant biology graduate Chris Hoggard began operating a commercial strawberry and raspberry farm in England in 1994, supplying large supermarket chains and smaller local farm shops with freshly grown strawberries and raspberries. In 1997, Agroleaf Ltd won its first order from ASDA (British subsidiary of Walmart) and continues to supply ASDA to the present day. In addition, Co-Op has joined the expanding group of nationwide supermarket chains selling his fruits. The company now has an annual turnover of approximately $3.1 million. The fruit and vegetable packing process has been considered to be an area of huge technological advances. Despite this progress, the packaging process is still reliant on the operators and what they consider to be target weights for each package they fill. The inconsistent nature of fruit and vegetables in terms of weight, shape and size means packaging can be a complex process. Many packaging facilities are now packaging in accordance with the average weight legislation (e mark) and, at the same time, making every effort to reduce giveaway.

` Agroleaf installed a total of eight dynamic average weight systems (four in view) and Vantage MES from SG Systems to control giveaways and keep electronic records for traceability requirements. Source: SG Systems.

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To get more consistent weights and comply with regulations, Hoggard originally purchased six Vantage DAWS (dynamic average weight systems) from SG Systems, but has recently added two more to the line because the investment paid for itself in reducing giveaways. SG Systems provides produce weighing and formula management equipment and software in the UK and US, and the installation of DAWS Vantage allows legal conformity of the finished packed product while decreasing giveaways. Vantage is a manufacturing execution system (MES) that provides formula control and management, traceability and operator performance metrics, and it interfaces to ERP systems. With DAWS, operators are required to weigh each product on a scale as they are guided through an ultra-responsive and quick weighing system. The eight weighing systems are networked to a management PC where traceability and yield information is stored for average weight conformity. Average weight legislation requires the batch average be at least equal to the declared weight. DAWS allows target weights to be continually adjusted in accordance with this legislation to ensure giveaway is reduced to almost zero. DAWS also produces a range of reports, giving a detailed and instant view of the operation at any given time. Typical reporting data relates to operator performance, line efficiency, product performance plus a variety of traceability reports for legal purposes. With the system, Agroleaf has reduced its 7 percent annual overweights to almost zero. “In addition to providing legal compliance, traceability and stock data, SG Systems has enabled us to turn our production yield goals and ambitions into reality,” says Hoggard. “Like us, it is a company that prides itself on being flexible. The supplier took a standard product and molded it to fit our process exactly, and we’re delighted with the financial improvement that DAWS has had on our bottom line” ❖ For more information: Jason Galloway, 214-819-9570, [email protected].

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FIELD REPORTS

Machinery integration accelerates condiment production

`

Servo-driven case packer not only speeds packaging, it also improves quality and overall productivity.

M

ullins Food Products develops, manufactures and packages the condiments found in many leading fast food restaurants. The company produces a large volume of packets, so any speed improvement in the packaging line can lead to noticeable results. One area needing improvement was the method for packing dipping sauce into larger cases for shipping, because this end-of-line process largely determines the overall speed of the line. To better meet its customers’ demands for oneounce cup products, Mullins commissioned a new case packing machine capable of quickly picking and placing the cups in cases for distribution. It purchased a high-speed three-axis case packer made by Soleri Design/Automation Inc. equipped with a highperformance servo system from the Bosch Rexroth Corporation Electric Drives and Controls group. Designed to accelerate speed across the entire production line, the Soleri case packer and corresponding Rexroth components integrated with an upstream, previously installed cup-filling machine from Win-

` This interior view of the Soleri packaging machine shows the lifting of 50 filled cups (right of carton) and the picking and placing of the slip sheet (left of carton) as they are alternately placed in the carton. The machine integrates with an upstream Winpak filler via a Rexroth controller. Source: Bosch Rexroth.

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pak. With this integration, Mullins significantly accelerated the overall speed of its cup line. “In an industry governed by speed, the Soleri machine immediately produced a sizeable increase in cycle speed,” says Mullins Maintenance Manager Larry Coons. When the filled one-ounce cups travel down the production line toward the packaging area, 50 containers are picked up with a suction head, oriented and placed into the case. A separate pick head places a cardboard slip sheet between each layer of cups to add strength and ensure the cups are not damaged during shipment. There are five layers, providing a total of 250 cups per case. The machine is driven by Rexroth IndraDrive digital servo drives and MSK servo motors. The drives provide distributed intelligence to close all the loops in the drive, freeing up the controller to calculate and execute the pick-and-place path planning. A key component of the system is the Rexroth PPC-R controller, a motion and logic controller that resides upstream on the Winpak cup-making machine. This system synchronizes all of the servo motions. It controls both the Winpak cup machine and the Soleri case packer. As a result, the speed of each machine directly corresponds with the tempo of the other one. “In terms of calculating production, we are ultimately measured by cycles per minute, and with this case packer, our throughput times have accelerated nicely,” says Coons. “Prior to the install of the Soleri machine, we maxed out at around 58 to 60 cycles per minute. We’re now running at least 70 cycles per minute—about 17 percent faster production.” Coons says package and product waste have improved also. With the servo system, the machine is designed to move slightly slower while the cups are en route to the box, but faster on the return to pick up more cups. This overall, controlled action reduces the potential for lost or damaged products, a number which Coons says has dropped by nearly 10 percent. ❖ For more information: Dan Throne, 847-645-3600, [email protected].

FIELD REPORTS

A chocolate a day keeps the doctor away

`

Making healthy chocolate requires a more sophisticated machine than the doctor first realized.

W

hile the words, “healthy chocolate,” might seem an oxymoron, the Healthy Chocolate Company of Sarasota, FL stands by its name, specializing in the production of nutritious artisan chocolate that doesn’t compromise on taste. The company’s secret lies in disguising health-supporting ingredients, including herbs and organic substances, in a dark chocolate bar. Physicist and President of Healthy Chocolate Dr. Aharon Friedman formulated the chocolate recipe after enduring his own struggle with diabetes. Friedman sought a way to incorporate this herbal formulation into food that would be of interest to those suffering from obesity or diabetes, especially children. Unfortunately, the herbs and ingredients Friedman was working with weren’t tasty, especially by a child’s standards. Because chocolate is a universal treat enjoyed by people of all ages, it presented an opportunity for Friedman. “The obvious problem with making chocolate healthy is that sugar comprises half of its ingredients, which is hardly a help to people already overweight,” says Friedman.

` Dr. Friedman stands by his healthy chocolate-making machine from Netzsch Premier Technologies, LLC. Coming soon is an even bigger machine to help satisfy his chocolate-loving customers’ appetites. Source: Netzsch Premier Technologies, LLC.

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“I began considering xylitol, which is classified as a sugar alcohol, but has the nearest chemical composition to glucose, a natural substance in the body,” he says. “Unlike other sugar alcohols, xylitol doesn’t cause extra work for the liver.” But xylitol is problematic as an ingredient. The alkaline solution introduced during the chocolate-making process to neutralize acidity caused xylitol to oxidize quickly, leading to a release of water, a hardened mixture and a burning taste caused by free carbon. It took almost three years to overcome this limitation. “At the time, we felt making the chocolate ourselves was far too costly, so we thought our only option was to rely on a supplier for bulk couverture and conching,” Friedman says. Healthy Chocolate continued using its supplier until Friedman met a fellow chocolatier who introduced him to a piece of equipment called the ChocoEasy, which would allow his team to manage conching themselves. The ChocoEasy, developed by Netzsch Premier Technologies, LLC, is a compact, automated chocolate-making system that produces repeatable batches of chocolate from any recipe. The machine is energyefficient, reducing energy costs by up to 35 percent compared to similar equipment. “Working with Netzsch, we were able to tailor the chocolate-making machine to give us tight temperature control, which is critical to our recipe. We can also make different batch sizes and get down to small particle sizes without over-pressuring the herbs,” Friedman says. “Getting our ingredients down to a smaller particle size has actually led to better consistency and a creamier chocolate,” he adds. Currently, Healthy Chocolate is using the ChocoEasy50, which allows Friedman’s team to produce 110 pounds of chocolate in each batch. On order is the ChocoEasy750, which will produce more than 1,600 pounds of chocolate in a single batch. ❖ For more information: Harry Way, 904-548-9837, [email protected].

FIELD REPORTS

Processor finds one-stop shopping

`

Gourmet pasta and sauce manufacturer searches for a continuous grilling oven and finds a spiral freezer as well.

J

oseph’s Gourmet Pasta & Sauces, located in Haverhill, MA, has experienced consistently rapid growth since it began handcrafting ravioli and sauces in its family-owned Italian bakery in the 1990s. After a few years, Joseph’s was confronted with the challenges of meeting quantum growth while maintaining the quality flavors and handmade appearance of its products. “We have a passion for offering the best products and services,” says Joe Faro, CEO and president. “For example, our fillings have unique, made-from-scratch flavors that reflect Old World ingredients and rustic, handmade preparation.” With increasing volumes and a proliferation of recipes, it became necessary to further automate the production process while meeting stringent food industry standards. “We were determined not to lose the handmade appearance and chef-prepared fillings and sauces,” Faro explains. “So we were extremely careful when considering automation, including the experience of the equipment supplier.” Joseph’s wanted to automate a line for openflame roasting, baking, searing and chilling. The items processed on the line include vegetables and other ingredients for sauces and ravioli fillings. In addition, quick-freeze equipment was needed for ravioli products.

` Joseph’s was determined to invest in customized cooking and refrigeration equipment such as this brander/searer (left) and spiral freezer (right) to maintain the handmade quality of its pasta and sauces. Source: Unitherm.

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Faro conducted his research and evaluation of equipment along with David Gillen, the processor’s vice president of culinary operations and manufacturing, who is also a trained chef. “We did considerable research on the project, and then began to consider suppliers,” Faro explains. “One we were particularly interested in was Unitherm Food Systems.” Initially, Joseph’s was looking only to find a vendor that could supply a continuous grilling oven. However, when Faro and Gillen saw custom spiral freezers in production at Unitherm, they were impressed. “We examined Unitherm’s spiral freezers and saw the robustness and design flexibility of the equipment,” says Gillen. Faro, Gillen and the other project team members met with Unitherm’s fabrication engineers and worked out a preliminary design, based mainly on the team’s insights. Although many food manufacturers often consider the chilling and freezing process that follows cooking to be a fixed quantity, the Joseph’s team wanted to understand the impact of both chilling and freezing product when airflow and temperature are manipulated. “At that point, we developed some specifications and talked about how the equipment would operate,” Faro explains. “We had some challenges like you do with anything that is custom made. But they stuck with it, and we moved through those hurdles very smoothly—then set to work on the project.” After the processor’s crew returned to Haverhill, the vendor’s engineers continued to fine-tune the design of the new line. The key to making those changes was a collaborative effort between the equipment design engineers and Joseph’s engineers and process managers. “The 3D modeling was a very convenient way to visualize different modifications in great detail,” Faro says. “It enabled us to work very conveniently on modifications and approvals, so that we were sure the system would work well for us in the long run.” ❖ For more information: Adam Cowherd, Unitherm, 918-367-0197, [email protected]

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FIELD REPORTS

Metal detectors provide reliable sensitivity, zero downtime

`

Meat processor puts metal detectors to the test and finds one that works with a wide range of products.

K

unzler & Company, a family-owned business, manufactures more than 500 meat products including hams, franks, bacon, luncheon meats and specialty items found in retail stores, restaurants, entertainment venues and other outlets throughout the US. For more than 100 years, Kunzler has been committed to producing the finest-quality products. To meet this standard, the processor decided to purchase three new metal detectors. “Our applications challenge metal detectors because we run a wide range of products with varying sizes, densities, moisture and salt content on each line,” explains Rodney Shultz, facilities manager at Kunzler’s Tyrone, PA manufacturing plant. “We considered metal detectors from two vendors and brought equipment from both into the plant for a side-by-side comparison. Our primary focus was detection sensitivity across our product range. We selected the PowerPhasePRO from Mettler-Toledo Safeline.”

` Kunzler assures safety in its meat products by running them through Safeline PowerPhasePRO metal detectors, which operate on three frequencies simultaneously to detect a wide range of metals. Source: Mettler-Toledo Safeline.

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“The first Safeline metal detector performed so well, we purchased two more for two other production lines,” adds Craig Dutrow, operations manager at the Tyrone plant. The PowerPhasePRO metal detector operates with three simultaneous frequencies, which achieves the highest sensitivity across a broad range of products by automatically accommodating variations. The metal detector allows a family of products (product clustering) to be run with no operator intervention during changeovers without sacrificing sensitivity. High-frequency coil technology and advanced head geometry work on all types of metal contamination, from ferrous and non-ferrous tramp metal to difficultto-detect stainless steel fragments. A Faraday screen located between the detector coil system and the product being inspected filters out interfering signals that might cause false-positive indications. “We test the sensitivity of each metal detector at every changeover and at least once a day,” says Dutrow. “It takes only 30 seconds to change over the PowerPhasePRO metal detector. We can either pull down a preprogrammed product recipe or we can auto-learn each product.” During its production shift, Kunzler keeps the room at 36° to 38°F. During the sanitation shift, the high-temperature, high-pressure washdown causes the temperature and humidity in the room to soar. To operate reliably, the metal detectors must handle these temperature extremes. They must also be watertight so the electronics are not compromised. Featuring an IP69K-rated control panel, the PowerPhasePRO metal detectors exceed NEMA 4X specifications. “At Kunzler, our highest priority is assuring a wholesome, safe product for our customers,” concludes Dave Grazier, vice president and general manager. “The Safeline metal detectors have helped us achieve just that with perfectly reliable sensitivity and zero downtime.” ❖ For more information: Sarrina Crowley, 813-889-9500, [email protected].

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Baldor is the largest motor and mechanical power transmission company in North America and the second largest worldwide. Baldor•Reliance® motor products now range from 1/50 horsepower through 15,000 horsepower. Dodge® power transmission products include a wide variety of engineered mounted bearings and enclosed gear products. The addition of Maska® pulleys and couplings provides even more solutions as part of the Baldor product line. Baldor products are primarily manufactured in plants throughout North America; however, the company owns and operates plants in England, China and Canada as well. Products are available 24 hours a day, every day of the year, from sales offices and warehouses throughout North America, Europe, Latin America, Asia, the Pacific Rim and Australia. Products are sold in more than 70 countries to distributors and original equipment manufacturers in more than 160 industries. Baldor products, marketed for more than 100 years, have exceptionally strong brand recognition for quality and value with our customers. Baldor continues to lead the industry in delivering timely and complete product information to customers through our customer-preferred web site, as well as numerous printed catalogs. We also offer many training classes for distributors and end-customers to help them learn our products, technologies being used, application solutions and Baldor’s competitive advantages. Over 15,000 students have benefited from this training in the past 10 years. Baldor has an on-going commitment to employee education. Baldor employs approximately 8,000 employees worldwide and believes that well-trained employees make a better product. We also believe that better products translate into better value for our customers and shareholders. We have been elected by Training Magazine as one of the top 100 training companies in America. Many years ago, Baldor carefully defined “Value” in terms meaningful to our customers. Value is defined in terms of Quality and Service (both as perceived by the customer) in relation to Cost and Time. The result is our “Value Formula” which has become a part of our culture. It guides our thinking and directs our work every day.

Contact: For more information about Baldor, visit our web site at www.baldor.com

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Bimba

Breddo Likewifier

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.

Breddo Likwifier, division of Caravan Ingredients, has been marketing the Likwifier stainless steel blender for 50 years. The machine was introduced to the Dairy Industry in 1958 as the Lanco Likwifier. In 1977, the name was changed to the Breddo Likwifier.

If you’ve got an engineering challenge, Bimba has the solution. Whether it’s a standard off-the-shelf cylinder or a cutting-edge custom assembly, Bimba is uniquely positioned to help you take control of any motion control application. In addition to its broad line of standard catalog products, Bimba also develops many custom and semi-custom products designed for specific customers and applications.

The Breddo Likwifier is designed to dissolve solids or semisolids where time, temperature and complete hydration are important. Originally developed to dissolve natural gums and synthetic thickeners used in the manufacture of frozen desserts, the Likwifier dissolves and disperses virtually any food product. The unit will put into solution, not just suspension, products that can be dissolved by agitation.

The Original Line Electric Actuator This revolutionary design is built and tested to provide the greatest durability, highest speed and most thrust per dollar. These cylinder’s superior execution in applications requiring increased control and flexibility make the OLE ideal for various food processing applications. Roundline Repairable Stainless Steel Cylinder The round, smooth—bodied design prevents potential sources of bacteria growth and contamination and has proven ideal for washdown environments. Designed specifically for food processing applications, this is the only cylinder that meets USDA regulations. Valves From solenoid air valves to button valves, Mead Fluid Dynamics has the technology to handle the most demanding pneumatic control applications. An innovative approach to design allows these corrosionresistant valves to perform even in tough wash-down environments, while still yielding smooth speed and control.

Contact: Telephone: 708-534-8544 or 800-44-BIMBA Fax: 708-235-2014 [email protected] www.bimba.com

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The benefits of the Breddo Likwifier include dissolving soluble products in less than 5 minutes, complete hydration; total product liquefaction; elimination of solid “burn on” in the vat; elimination of waste at strainers and tank bottoms; and the complete dispersement of insoluble particles in water or non-aqueous media. The following products can be processed by the Breddo Likwifier at high concentrations and in a few minutes: stabilizing gums, emulsifiers, flours, cocoas, yeast, powdered eggs, starches, condiments, caseinates, juice concentrates, food purees, whey solids, frozen products and cheese slurries. Breddo Likwifiers are being used in the food industries to manufacture ice cream mixes, candies, reconstituted products, canned condiments, sauces, salad dressing, fillings, instant breakfast, and many other similar items.

Contact: Don Wolfe, ext. 1162 BREDDO Likwifier 1230 Taney St Kansas City, MO 64116 800-669-4092 – phone 816-561-7778 – fax www.breddo.com

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Burns & McDonnell A Total Project Solution™: We See It Clearly Burns & McDonnell delivers Total Project Solutions™ for the food and consumer products industries. From preliminary engineering through procurement, construction and commissioning, Burns & McDonnell assists clients with fast-tomarket, innovative solutions. Our expertise includes design-build installation, process and packaging design, facility audits, alternative energy sources, food safety, new product rollouts, wastewater, HVAC design, ammonia refrigeration, HACCP reviews, and comprehensive environmental services. Moreover, our LEED®-accredited professionals provide green solutions to meet your sustainability goals. Commitment to Partnership Our mission is to “Make Our Clients Successful!” A full range of integrated services allows Burns & McDonnell to be flexible when projects change and successfully meet our clients’ needs. Our success in making our clients successful was affirmed by The Professional Services Management Journal. The Journal recently completed an independent survey of Architectural-Engineering-Construction (AEC) clients to determine their level of satisfaction with their AEC services firms. Burns & McDonnell was named one of only six firms nationally to receive the Premier Award for Client Satisfaction. Predictable Outcomes Founded in 1898, Burns & McDonnell Engineering Company, Inc. is an internationally recognized engineering, architecture, construction, environmental and consulting solutions firm. The company maintains branch offices throughout the United States and services clients around the globe. Since 1986, Burns & McDonnell has been a 100% employee-owned firm with each employee-owner taking an active interest and involvement in the performance of the firm. The food & consumer products team at Burns & McDonnell is comprised of personnel with diverse backgrounds that equip them to meet the diverse needs of our clients. Team members have practical experience with respected companies in the industry and understand the type of engineering necessary to execute projects in an efficient and cost-effective manner to produce predictable project outcomes.

Cablevey Conveyors Why use conveying equipment that damages your product? There are good alternatives to bucket elevators, open conveyor belts, augers and aeromechanical systems. Conveying easily broken materials is a challenge even under the best circumstances. It’s a serious problem, because the cost of damaged products can eat away at your plant’s budget and your company’s bottom line. Our versatile tubular cable conveyer offers you important advantages. It uses NO air to convey your materials. Consider… Cable & discs move a wide variety of food materials. They can convey coffee, nuts, rice, cereal, grains and blends safely and efficiently without the use of air, expensive filter systems or excess horsepower. Blended materials present a special challenge. Sometimes the integrity of the mix needs attention. Other times, heavier components in the mix fall backwards while the lighter elements forge ahead. Your packaging process can improve greatly with better control of these materials.

Compare for yourself: • Vacuums & pneumatic conveyor systems often consume 10X the energy of tubular drag cable conveyors. • Bucket elevators can cause significant maintenance downtime for time cleaning buckets and replacing small parts. • All of our systems are customized layout designs typically using multiple inlets and discharge points. • Our systems eliminate or dramatically reduce product separation & degradation. • No filters are needed! Dust-free conveying means materials stay inside the tubes. • Standard systems convey up to 1240 cubic ft/hr (35 M3/ hr.).

In short, Cablevey Conveyors can replace Bucket Elevators, Screw Conveyors, Pneumatic and Aeromechanical Systems. Think Cablevey - The Gentle Way to Convey. Link: http://www.cablevey.com

Contact: Caroline Cooper Burns & McDonnell 9400 Ward Parkway Kansas City, MO 64114 816-822-3831 [email protected] www.burnsmcd.com/fcp

Contact: 641-673-8451 www.cablevey.com

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

DCI, Inc.

Douglas Machines Corp.

DCI, Inc., an employee owned company, has been a leader in the design, manufacturing and servicing of stainless steel/ other alloy equipment since 1955. The sizes and shapes of DCI manufactured equipment are as varied as the customers we serve. From 5 gallon process vessels to 500,000 gallon field-fabricated tanks, DCI tanks process, blend, store, heat, cool, mix and ferment the most trusted products and brands in the market. As a custom fabricator, we proudly serve the food, dairy and beverage industries with: • Tanks/Vessels (silo tanks, processors, starter tanks, whey crystallizers, round horizontal tanks, mix/blend tanks, • Dynamixer & Dynamixer Processor tanks, and DCI Site-Fab field-fabricated tanks). • Mixers/Agitators • Manways, Heads, Components • Replacement Parts • Field Service/Repair

Douglas Machines Corp. offers

The DCI Dynamixer is designed to mix dry solids, semi-solids or liquids into a slurry or liquid product. This high speed mixer/blender may also be used to blend, disperse, reconstitute, dissolve, re-hydrate, prebreak or rerun soluble solids, soluble pastes and liquids quickly, efficiently and completely. Insoluble products are dispersed into liquids to make suspensions and slurries with greater stability and homogeneity. Models are available in a variety of shapes, sizes and motor horsepower to fit a broad range of applications. DCI’s Dynamixer Processor combines all the features of Dynamixer high speed mixer with the benefits of a cone bottom processing tank. It can perform three separate process functions all in the same tank. Mixing dry or semi-solids into a liquid, chopping and chipping solids, and heating and/or cooling the mixed batch.

for bulk ingredient bins, and

Contact: DCI, Inc. – Corporate Headquarters 600 North 54 Avenue (56303) P.O. Box 1227 (56302-1227) St. Cloud, MN – USA Phone: (320) 252-8200 Fax: (320) 252-0866 [email protected] www.dciinc.com

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a full line of automated washing and sanitizing equipment for all containers commonly used in the food processing and distribution industries. Batch and continuous cleaning designs are available for several hundred to several thousand containers per hour. Pictured are some of their most recent product introductions; a Rack Washer for detachable weigh scale parts, a Vat/Bin Washer a Tunnel Washer for Pallets. Other models are available for barrels, pans, trays, moulds, totes, screens, smoke sticks, racks and buckets. Call 800-331-6870,

or

visit

www.dougmac.com to get additional information on a model suited to your specific needs

Contact: Douglas Machines Corp. 2101 Calumet Street Clearwater, FL 33765 Phone: 800-331-6870 or 727-461-3477 Fax: 727-449-0029 Email: [email protected] www.dougmac.com

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Eriez

Evergreen

Feeders and Conveyors

New EQ-70 gable top packaging machine from Evergreen Packaging ELL® features maintain product quality

Eriez conveyors are rugged, efficient, high capacity units that move large volumes of bulk material reliably and economically. There are mechanical and electromagnetic models available.

Magnetic Separators • High performance Rare Earth • Electromagnetic filtration systems • Sanitary easy-to-clean systems Magnetic separation equipment includes magnetic plates, grates and traps. They protect your equipment and product purity by removing fine particles and larger tramp metal from dry, free flowing products or in liquid and slurry lines.

Metal Detectors and Inspection • Metal detection and X-Ray equipment • Liquid, dry and packaged goods Eriez metal detectors are capable of finding ferrous, nonferrous and stainless steel metals by utilizing the highest level of sensitivities ava ilable for dry and liquid product processing. Eriez’ E-Z Tec XR Series X-Ray inspection equipment delivers the highest level of product and packaging integrity. The systems employ advanced linear array technology for superior sensitivity and speed and provide real-time analysis of goods requiring high levels of product integrity. Systems monitor package attributes such as count, weight, fill level and product integrity, and detect unwanted metals, stone, glass and plastics.

Contact: 1-888-300-ERIEZ (3743) www.eriez.com [email protected] 2200 Asbury Road Erie, PA 16514-0608

CEDAR RAPIDS, IA, USA – Evergreen Packaging Equipment manufactures a full line of filling equipment for refrigerated dairy, juice and liquid food products. Gable top packaging equipment, which forms, fills and seals paper gable top cartons, is ideal for pasteurized, ESL (Extended Shelf Life), ELL® (Extended Long Life), and hot fill applications. These machines fill cartons from 4 oz. up to halfEQ-70 gallon (150ml up to two liter), at speeds from 30 up to 340 cartons per minute. SPOUT-PAK® twist-off closures are also available for most gable top cartons. Evergreen introduced the new EQ-70 gable top packaging machine at IDS 2010, which will be commercially available in 2012, designed to serve liquid food markets. ELL® (Extended Long Life) components include a self-contained CIP/SIP system, environmental control features, carton treatment and a hermetic filling system to maintain product quality. With fill volumes of 6 to 32 oz (180ml to 1.15L), the EQ-70 fills quarts/liters up to 7,000 cph (117 cpm) and fractionals up to 9,000 cph (150 cpm) with a three-stage top down fill system. Servo driven technology provides repeatable package performance and automatically controls fill volumes and profiles based on product and carton size. Infinite fill adjustments allow for less down time with quick and easy changes to fill volume and carton height. The N-100 serves the school milk, single serve food service and convenience store markets. With fill volumes of 4 to 16 oz (125 to 500ml), the new Eco-Pak® machine fills 4 to 8 oz. (125 to 250ml) cartons up to 10,200 cph (170 cpm) and 10 to 16 oz. (300 to 500ml) up to 8,500 cph (142cpm). The Q-70 serves the small to mid-size volume market. With fill volumes of 6 to 32 oz (180ml to 1.15L), the Q-70 fills quarts/liters up to 7,000 cph (117 cpm) and fractionals up to 9,000 cph (150 cpm) to meet market demand for a mid-speed quart/liter cross-section machine. To ensure that these machines keep running efficiently, Run Time™, a comprehensive parts and service program provides genuine Evergreen parts manufactured to OEM specifications to maximize production, reduce risk of product loss and protect equipment warranties. The company stocks an extensive inventory of critical parts and offers 24/7/365 availability for emergencies. A network of fully-trained, experienced technicians is established to handle any size service request.

Contact: Evergreen Packaging Equipment 319-399-3306 [email protected] www.evergreenpackaging.com

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Fortress Technology Inc.

FPEC

Fortress Technology Inc. was pleased to participate as an Exhibitor in the 2010 Pack Expo Trade Show. Everyone agreed that the Show was a great success and the turn-out was one of the most successful in years. Fortress displayed the “all-in-one” Vector Conveyor; Gravity, and Pipeline units.

The metal detection solutions exhibited satisfy a variety of industries including: Bakery, Dairy, Meat and Poultry applications. Fortress PHANTOM metal detectors can also be customized to suit a company’s unique production line. Manufactured with the main principles of simple operation, outstanding reliability, and exceptional performance; PHANTOM metal detectors are built rugged to withstand the harshest washdown environments and have a certified IP69K rating on stainless steel units. Easy-to-use PHANTOM systems, with powerful digital signal processing (DSP), provide fast, accurate detection of ferrous, non-ferrous, and stainless steel metals. System enhancement via CONTACT Data Logging software with wireless connectivity enables communication with a PC to make the metal detector a critical control point in HACCP programs.

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

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Visit us at IPE Booth # 5443

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Fristam Pump

GEA Westfalia Separator, Inc.

Fristam stainless steel pumps, blenders and mixers are designed for precision and durability to outlast and outperform all others and provide the highest lifetime value. With unmatched knowledge and experience, we partner with you for custom innovative solutions.

Founded in Germany over a century ago, GEA Westfalia Separator offers a full range of products in the dynamic filtration and separation categories, including high performance separators, clarifiers, decanters and membrane filtration systems. We specialize in applying our technologies to the dairy, beverage and edible oil industries. Our equipment can be found in small and large food processing facilities. For small installations we offer Westfalia Separator ecoplus, a concept based on modular machines that can be upgraded as processing volumes increase. At the other end of the spectrum is the MSE 600, the largest dairy separator in the world.

New Heavy-duty Positive Displacement 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 nodisassembly-required “True CIP”. Its balanced rotors and large-diameter shafts make it durable and reliable. Powder Mixer Fristam’s Powder Mixer blends dry and wet ingredients into a fluid stream. This quick and efficient mixing method maintains performance even as product viscosity increases. The Fristam Powder Mixer is customizable and provides consistent batch-to-batch repeatability and dramatically reduced blend times. Shear Blender FS Shear Blenders improve product consistency by removing agglomerates and preventing lumps and masses in product. It offers repeatable results and reduces raw material usage and processing times. The FS is CIP’able and features a front pull-out seal for in-place maintenance. Additional Fristam products: • FL II series PD pump for gentle product handling. • Easy-maintenance FPR series centrifugal pump, with front pull-out seal. • Heavy-duty FP series centrifugal pump. • Standard-duty FPX series centrifugal pump. • High-pressure FM, FPH and FPHP series pumps for discharge pressures to 1,250 PSI. • FZX series self-priming pump for CIP return and pumping aerated products.

Contact: Fristam Pumps USA 2410 Parview Road Middleton, WI 53562 800-841-5001 www.fristam.com/usa

We also offer Westfalia Separator capitalcare, a program developed to protect our customers’ investments. This all encompassing program includes original spare parts, around-the-clock service and factory authorized repair facilities. Our goal is to ensure safe operation and maximum performance over the life of the equipment. Westfalia Separator wewatch, is another special program. This remote data collection and transmittal system continuously records centrifuge vibration and process data and interprets its meaning. It allows our customers to eliminate unscheduled downtime by predicting and preventing equipment failures and diagnosing the root cause of a problem.

Contact: GEA Westfalia Separator, Inc. 100 Fairway Ct. Northvale, NJ 07647 Phone: 201-767-3900 E-mail: [email protected] www.wsus.com

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Harpak-ULMA Packaging, LLC

Heat and Control, Inc.

Harpak, Inc. and ULMA Packaging Systems, Inc., suppliers of packaging solutions in North America announced the completion their merger on July 19, 2010. The company has a new name going forward, Harpak-ULMA Packaging, LLC.

Improve processing, inspection, conveying and packaging quality and efficiency with the latest machinery from Heat and Control. New equipment featured in our booth includes: • Ishida tray sealer – Versatile system produces high quality, hermetically sealed trays at up to 200 ppm. • CEIA THS-21 metal detector – Self-calibrating system consistently delivers the highest sensitivity to all metals. Economy models also available. • Ishida sticky products weigher – Sanitary multihead weigher with double screw feeders reduces overweights to near-zero for fresh meat, poultry, and other foods. • FastBack horizontal motion conveyors for weigher feeding, distribution, product blending, sizing, and storage. • Sanitary packaging platforms – Built to AMI specifications, these structures for weighers and conveyors reduce installation and cleaning costs. • AirForce impingement, spiral & convection ovens – Cook foods uniformly across the conveyor width for safe, high-yield production. • MasterTherm fryer – Thermal fluid heated design evenly heats oil throughout the fryer for uniform cooking. • Ishida X-ray inspection systems – Accurately detect metal, plastic, shell, stone, and other contaminants, plus product defects, without using expensive customized software. • Ishida snack bagmakers – Make perfect seals and a variety of bag sizes at high speeds with a low life cycle cost.

Harpak-ULMA offers leading edge technology for all your packaging and automation needs, backed by years of experience. Our range of products includes form/fill/seal, tray sealers, flow wrap, shrink and vertical bagging equipment. Our broad range of equipment is the widest and most comprehensive in the industry. Over the years we have developed unique solutions for a variety of packaging applications. By combining our offerings through a single distribution system we are now able to meet more of our customers’ requirements. Harpak-ULMA packaging capabilities include food, fresh food and non-food packaging, complete MAP solutions (denesting, filling, sealing) and unique applications in both rigid and flexible formats. This combination of capabilities allows Harpak-ULMA to offer our customers a wider range of fully integrated packaging solutions and superior technical support. Our customers now have easy, one stop access to the “best of the best” across all types of packaging machinery to efficiently meet their needs. The combined strength of the two companies allows Harpak-ULMA to offer total packaging solutions customized to each customer’s specific application. We look forward to continuing to work with our customers as we increase the range of packaging machinery and level of support we offer.

Heat and Control is a single source supplier of complete food machinery systems. We provide fryers, ovens, cookers, batter/ breading applicators, branders, searers, seasoning applicators, conveyors, tray fillers, Ishida weighers, checkweighers, snack bagmakers, and X-ray inspection systems, CEIA metal detectors, pilot plant and food service equipment, and control systems integration, plus product demonstrations, service, spare parts, training and technical support from over 30 offices worldwide. Contact: Harpak-ULMA Packaging, LLC 175 John Quincy Adams Road Taunton, MA 02780 Tel: (508)884-2500 Fax: (508)884-2501 Toll Free: (800)813-6644 URL: www.harpak-ulma.com

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Contact: 21121 Cabot Blvd., Hayward, CA 94545 Phone: 800-227-5980 / 510-259-0500 Fax: 510-259-0600 [email protected] www.heatandcontrol.com

See us at IPE Booth # 4430

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Hinds-Bock Corporation

JAX INC.

Hinds-Bock Corp. is dedicated to meeting the needs of the food processing industry with highquality piston depositing and filling equipment, pumps, lidders, form/ fill/seal and custom solutions. The company’s equipment ranges from small tabletop depositors to high-volume industrial lines, which include tray and paper cup denesters, pan oilers, large intermediate hoppers, servo-driven conveyors and PLC controls. From simple stand-alone units to complex systems, we design solutions for your most demanding filling and depositing needs. Solutions like placing gravies and sauces on prepared fish, meat or chicken to create Value Added Entrees. Hinds-Bock’s engineering staff designs custom equipment using the latest CAD 3D modeling systems to meet specific customer needs. In-house technicians and engineers provide on-site installation and turnkey start up support for custom designed equipment. Hinds-Bock manufactures standardized and custom piston filling and depositing machines and systems as well as piston transfer pumps. This equipment ranges from single piston fillers and simple air-powered transfer pumps to turnkey, custom multi-lane, conveyorized, computer controlled, high-speed production systems. Many options are available including heated or cooled machines, hopper agitation, diving, traveling or orbital spout movement and pressure fed machines for extremely viscous products.

Founded in 1955, JAX INC. manufactures the industry’s highest-quality food-grade, synthetic, heavy-duty and general industrial lubricants. JAX has led the industry with recent advances in the areas of high-end synthetic and food plant lubricants. We use only the finest NSF-registered H1 synthetic base stock blended with stateof-the-art additive technology designed to decrease machinery downtime and reduce lubricant consumption in order to ultimately increase the life span of equipment. With our full line, JAX has existing products and also the industry expertise and experience to tailor our lubrication technology to your specific needs. Most notably, JAX revolutionary line of Halo-Guard® FG greases combines an advanced, proprietary calcium sulfonate complex thickener and new high-viscosity, partial and full synthetic food-grade base fluids in order to provide unmatched performance on heavily-loaded applications. While we may gain most recognition for our lubricants, JAX is truly a turnkey solutions provider, covering the full spectrum of your needs. Our industry-leading lubricants are only the beginning. Xact Fluid Solutions division engineers automated fluid-dispensing solutions tailored to specific requirements and plant applications. In addition, the Xact Lube-Guard Program offers a comprehensive approach to clearly identifying each lubricant, its proper application and the lubrication maintenance schedule in your plant. The process is guided by our color-coded wall charts, lube tags and safe storage containment systems. In JAX independent RPM laboratory, our technical staff recognizes the ever-evolving nature of lubrication technology and is relentlessly researching ways to improve our industry-leading product line. In addition, our used oil analysis program keeps your machines running smoothly by identifying internal component wear issues before unscheduled downtime takes a toll. JAX RPM Lab delivers exceptional turnaround time on received samples, reducing the worries associated with plant maintenance. Pressure-Lube Inc. manufactures the finest industrial aerosol maintenance products in the industry with a full line to meet the requirements of any application. In addition, JAX new food plant-friendly, color-coded packaging clearly identifies H1 products to take the safety guesswork out of lubricant selection. Add to this equation a staff of the most knowledgeable and dedicated people in the industry and the result is clear: at JAX, our full line of products and services will meet and exceed all your needs and our dedicated, professional people will be there with you all the way.

In-house technicians and engineers provide on-site installation and turnkey start-up support for custom designed equipment and systems. We maintain complete documentation on every machine we build and support those machines with a thoroughly stocked parts department. We have a test facility to run customer provided samples of products to evaluate filling characteristics and determine agitation and spout requirements. Tests are typically videotaped so that customers can observe the deposit configuration. Frozen samples of deposited materials can also be returned to the customer. Contact: Hinds-Bock Corp. 2122 222nd Street SE Bothell, WA 98021 (877) 292-5715 (425) 885-1183 Fax (425) 885-1492 e-mail: [email protected] www.hinds-bock.com

Contact: JAX INC. W134 N5373 Campbell Drive Menomonee Falls, WI 53051 262-781-8850 Phone / 262-781-3906 Fax www.JAX.com

Visit us at IPE Booth # 4214 www.foodengineeringmag.com | Food Engineering | January 2011

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

JBT FoodTech

Key Technology

JBT FoodTech, a leading supplier of food processing solutions ranging from single machines to integrated processing lines, continues to improve its systems and strengthen its global partnerships to help processors meet their needs for quality, efficiency and yield. Poultry processors can find custom solutions to their specific needs with proven systems like the DSI Consistent Thickness Slicer™, Stein Ultra V™ Breader, Stein 5 Star Home Style™ Breader, Stein TFF THERMoFIN® Fryer, Stein GCO-II GYRoCOMPACT® Oven and Frigoscandia GYRoCOMPACT® M10 Tight Curve Spiral Freezer, among Double D others. Most recently – and Searer/Grill new since the last IPE show – Marker JBT FoodTech is offering the MX-II, a next-generation

As a leading manufacturer of process automation systems for the food processing industry, Key Technology helps customers improve product quality, optimize yield, reduce labor costs, and improve process control to enhance plant efficiencies.

MicroMAX™ filter and developed a DSI Adaptive 3D Portioning™ System that combines the new DSI Adaptive Slicer™ and DSI Waterjet Portioning System. In addition, JBT FoodTech now offers the Double D Searer/Grill Marker and is the exclusive sales agent in North America for the Odenberg Pallet-Link® chilling and freezing system. The Odenberg Pallet-Link® system allows for variable retention time and buffering for controlled parameter chilling and freezing of multiple products simultaneously.

• Optical Inspection/Defect Removal Systems – Manta® high volume sorters, Tegra® in-air sorters, Optyx® compact sorters, and Raptor/ FluoRaptor™ Laser Technology identify and remove defects and foreign material. onCore® is an integrated system for processing of iceberg and romaine lettuces in bagged salads. ADR® for potato strips removes defects. • Specialized Conveying Systems – Iso-Flo® vibratory conveyors, Impulse™ electromagnetic conveyors, Spiral-Flo™ elevators, and pumping systems. • Grading systems – Iso-Flo and Farmco equipment for sizing, grading, and separating. • Preparation Systems – air cooling, air cleaning, washing, and feeding. • Fresh-cut food processing equipment – washers, dryers, and integrated lines. • Services – application testing, custom engineering, installation and start-up, training, and customizable service packages for maintenance and repairs.

Odenberg Pallet-Link® System

Contact: JBT FoodTech Portioning, Slicing, Coating, Frying, Cooking, Freezing 1622 First Street Sandusky, OH 44870. Phone: +1 419 626 0304 jbtfoodtech.com

IPE Booth #4639

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Contact: Key Technology, Inc. 150 Avery Street Walla Walla, WA 99362 USA Tel: 509 529 2161 Fax: 509 527 1331 Email: [email protected] URL: www.key.net

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Lubriplate Lubricants Company

NuTEC Manufacturing

Lubriplate Lubricants Company is a producer of high performance, long life, synthetic lubricants. These lubricants provide superior lubrication and protection for all types of industrial machinery, food processing and bottling machinery as well as construction, automotive and marine equipment. The company has executive offices in Newark, New Jersey and manufacturing facilities in Toledo, Ohio. Lubriplate Lubricants are backed by an international system of local distributors. The company is ISO 9001 Registered.

What began in 1983 as simple patty forming with NuTEC’s 1-A machine has grown to a line-up that includes 5 different food formers with varying capacities and C-Frame Portioning Depositors for stuffed or filled products. In 2009, NuTEC introduced its Automatic Direct Depositing and Tray Indexing Conveyor. When configured with the NuTEC 720, the Tray Indexing Conveyor efficiently portions and deposits patties directly into trays at speeds of up to 65 trays per minute.

Of special interest is the major market position Lubriplate enjoys in the field of food processing and bottling machinery lubrication. These Lubriplate NSF H-1 Registered lubricants meet FDA regulations 21 CFR 178.3570 and 21 CFR 172.882. They are certified OU Kosher Pareve and HALAL registered. The manufacturing process for these H-1 lubricants is ISO 21469 Compliant. The use of Lubriplate H-1 lubricants throughout your plant operations can significantly simplify your HACCP program by eliminating lubrication as a potential chemical hazard. Sales, marketing and technical staff can be reached at 1-800-733-4755 or e-mail [email protected]. Their webpage is www.lubriplate.com. Specific lubrication questions can be addressed to [email protected].

The technology behind NuTEC equipment assures: • Perfect shapes • Home-made product quality • Consistent weight control • Better equipment dependability Food product applications include: • Beef • Chicken • Pork • Seafood • Veggie Patties • Skinless Links • Onion/Veggie Rings & Sticks • Nuggets & Strips • Meatballs • Stuffed Sandwiches • Layered Products A key piece of equipment to food processors, the C-Frame Portioning Depositor, was added to NuTEC’s product mix in 1990. This Depositor accurately and consistently deposits fillings for stuffed sandwiches, egg rolls, meat pies, appetizers, calzones, jalapeno peppers, and a wide variety of other products. Like most NuTEC equipment, it is also hydraulic and provides excellent portion weight control and clean, accurate filling placement up and down the line. 45,000 deposits per hour are attainable on certain models. NuTEC’s unique feed system uses a rotating spiral that gently moves the product to the rotary vane pump. Bridging and overworking are eliminated because the product is neither rolled nor tumbled. Deposit sizes of up to 1 3/8” thick can be achieved at up to 65 cycles per minute. The 100% hydraulic system on the C-Frame Portioning Depositor also minimizes maintenance, reduces downtime, and lowers repair costs.

Contact: Mr. Jim Girard, VP & CMO Lubriplate Lubricants Company 129 Lockwood Street NEWARK, NJ 07105 1-800-733-4755 www.lubriplate.com

Contact: NuTEC Manufacturing 908 Garnet Court New Lenox, IL 60451 Phone: (815)722-2800 Fax: (815)722-2831 www.nutecmfg.com email: [email protected]

See us at the IPE Booth # B5671 www.foodengineeringmag.com | Food Engineering | January 2011

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Parker

Quickdraft

Stainless Steel Filters for Wash Down Areas Balston® Stainless Steel Harsh Environment filters will remove 99.99% of oil, water, rust and pipescale particles of 0.01 micron in size and larger from compressed air and other gases. The filters are available in ¼” to 1” line sizes with flow capacities to over 700 SCFM. Constructed of 304 stainless, these filters will stand up to the harshest environments such as wash down areas. For additional information, please contact Parker Hannifin Corporation, 242 Neck Rd, Haverhill, MA 01835. 1-800-343-4048. www.balstonfilters.com

Since 1953 Quickdraft has provided its customers with pneumatic conveying systems and exhaust systems specifically engineered to solve customer production problems and to enhance their productivity and profitability.

Steam Filter Permits Direct Steam Contact with Food Balston® Steam Filters remove 98+ of 0.1 micron particles and100% of all visible particles from steam. Models are available to handle flow rates of up to 3,000 lbs/hr. Other benefits include: Reduction in steam condensate mixing with food products when steam is used for agitating, mixing or cooking; reduced maintenance requirements for valves, cookers, heat exchangers and other equipment. For additional information, please contact Parker Hannifin Corporation, 242 Neck Rd, Haverhill, MA 01835. 1-800-343-4048. www.balstonfilters.com Together, we can eliminate microorganism contamination. • Balston® Sterile Air Filters to remove all viable organisms • 99.9999+% at 0.1 microns – 30 times better than the accepted standard • Full compliance with FDA • USDA accepted for use in federally inspected meat and poultry plants • All 304 stainless steel construction • Ideal for washdown area

Contact: 1-800-343-4048

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Venturi At the core of Quickdraft’s offerings for both pneumatic Arrows in the blue airstream depict conveying and exhaust the injected air accelerating the systems is its venturi. With flow. Arrows in the red airstream the blower handling ambiindicate the material being conveyed. ent air and no moving parts in the conveying or exhaust duct, the venturi is a low-maintenance, dependable solution for a variety of applications. Pneumatic Conveying Systems Quickdraft’s pneumatic systems can safely convey edible and inedible product, scrap hot dog casings, packaging trim, cook-in bags, mechanically deboned meat residue or other material hundreds Hot Dog Casing Removal System of feet for further processing or disposal, with minimal operator interaction. Systems are designed for 24/7 operation and require little or no maintenance. Exhaust Systems Quickdraft’s venturi exhauster is an excellent solution where there are high-maintenance exhaust problems: where the exhaust is very hot or very cold, highly humid, highly corrosive or when the exhaust contains sticky particulates. With no moving parts in the air stream, the exhaust system is dependable requiring little maintenance. All components in contact Exhaust Filtration with the air stream are stainless steel. It is System an excellent exhaust solution for a variety of ovens, fryers, microwave ovens, and freezing tunnels. Our venturi can be paired with our grease demister which uses water and mechanical filtration to capture grease and other particulates in the air stream and prevent grease build-up on roofs.

Contact: Quickdraft 1-855-VENTURI [email protected] www.quickdraft.com

Visit us at IPE booth # 4322

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Marchant Schmidt, Inc.

If you have cable conveyors, we have your conveyor cable!

Marchant Schmidt is the largest and most complete source for conveyor cables. Call us for quality cable products at reasonable prices.

Introducing... ...our newest reinforced plastic cable. Reinforced with high-tensile synthetic cord, it outperforms stainless reinforced plastic cable! • Greater strength Allows for longer runs / heavier loads • Increased flexibility Allows for more turns / tighter turns • Longer service life... ...and no need for crimps or cover sleeves! Saves you money!

We stock all commonly used styles, so we can match the type and size you use. • Stainless or galvanized cables — as used extensively in canneries, with nylon coating or bare • Plastic cables — stainless reinforced, poly reinforced, or our new synthetic reinforced • Industry standard sizes, and highest quality materials

Serving food, beverage and related industries for almost 50 years.

920-921-4760 / FAX: 920-921-9640 or E-mail Lyle at [email protected]

www.foodengineeringmag.com | Food Engineering | January 2011

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Reiser

SEW-EURODRIVE

Reiser will feature live demonstrations of their poultry processing equipment at the 2011 IPE. Of special interest to poultry processors will be Reiser’s wide variety of Vemag processing solutions, including systems for ground turkey loaf forming, ball forming, and high-speed poultry sausage linking and hanging. Live demonstrations will highlight Vemag’s high-speed sausage linking and hanging system. Reiser will demonstrate the new Vemag LPG209 Length Portioning Machine with Twin Horns and an Automatic Casing Loading Magazine. The LPG209 features two rotating linking horns to significantly reduce casing change times and dramatically increase production of sausages with identical lengths and weights in both collagen and natural casings. With twin horns and an automatic casing loader, the LPG209 is the fastest linker in the industry. Reiser will also showcase their Vemag MMP220 Loaf Forming system. This inline solution integrates portioning, grinding, separating and forming into one operation. It is the perfect system for producing high quality loaves of ground turkey and ground chicken. The loaves are precisely portioned with a uniform shape and consistent, accurate weight. Reiser will also demonstrate its line of Fomaco Injectors for both whole birds and poultry parts. The Fomaco Injector not only provides the highest performance, it also raises marination yields to new highs.

SEW-EURODRIVE has been a pioneer in drive technology for more than 75 years, from the introduction of the world’s first gearmotor to the early development of electronic drives to our awardwinning drive-based automation solutions for the 21st century. SEW-EURODRIVE manufactures a complete line of high-performance gearmotors, variable frequency drives, servos and motion controllers. Our application specialists help baking industry professionals design power transmission and motion control systems for all applications and areas – from mixing and forming to conveying and packaging in wet, dry, hot and frozen environments. The harsh environments in today’s industrial bakeries punish equipment. Often, paints fail long before anything else. SEW’s new stainless steel KESA37 is performing reliably in caustic washdown environments. Efficient, long-life helical bevel gearing means these units run cooler, last longer, and use about half the energy of typical single-worm gear units. The material, design and finish mean high resistance to bacteria, chemicals and processes common to the baking industry. Modern plants need modern motor control. MOVIFIT® combines the advantages of decentralized control with the latest in drive application and communication technologies. Available in both standard IP65 and hygienic IP69K rated construction, MOVIFIT VFDs and motor controllers provide a flexible and highly scalable platform for plant-wide decentralized control in a wide range of wet and dry environments. MOVIFIT and the stainless steel KESA37 are great examples of how SEW-EURODRIVE works every day to create innovative power transmission and motion control solutions that help the baking improve productivity, safety and profitability.

Contact: Reiser 725 Dedham Street Canton, MA, 02021 Telephone: (781) 821-1290 Fax: (781) 821-1316 [email protected] www.reiser.com

Visit us at IPE booth # 6545

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Contact: Chris Wood SEW-EURODRIVE PO Box 518 Lyman, SC 29365 P: 804-740-2269 [email protected] www.seweurodrive.com

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Spraying Systems Co.

SPX

New Spray Technology Displayed by Spraying Systems Co. at IBIE Products and systems designed to ensure product quality and minimize waste in coating operations generated significant interest during the show. Visitors to the Spraying Systems Co. booth learned about new ways to consistently and uniformly apply non-viscous and viscous coatings such as chocolate, oils, sugar slurries and more. AccuCoat® Heated Spray Systems use closed-loop temperature control to ensure accurate application of viscous coatings up to 25,000 centipoise. The system offers many advantages over enrobing including reduced coating use – by as much as 50% – and less maintenance and downtime. AutoJet® Anti-Mold Spray Systems provide accurate delivery of antimold agents on bread products. The system uses PulsaJet® automatic spray nozzles for precise, clog-free application of mold-inhibitors, SprayCheck® sensors to verify each spray cycle and automatic ratio, mixing and recirculation to ensure consistent concentrations. Sanitary, Heated Spray Headers are ideal for use with even the most difficult-to-apply coatings like marshmallow cream, egg wash, cheese and more. The headers are of sanitary construction, can be equipped with hydraulic or air atomizing nozzles and can be jacketed. Automated Coating Systems improve quality and lower operating costs by controlling automatic spray nozzles. AutoJet® Model 1550 Modular Spray Systems ensure accurate spray placement and maintain proper flow and drop size to eliminate waste and uneven coating. The system is selfcontained and can be set up in minutes.

Contact: Spraying Systems Co. North Avenue and Schmale Road P.O. Box 7900 Wheaton, IL 60187-7901 USA 1-800-95-SPRAY 1-888-95 SPRAY (fax) www.spray.com [email protected]

SPX’s Flow Technology segment designs, manufactures and markets engineered solutions and products used to process, blend, meter and transport fluids as well as gas filtration and dehydration equipment. Our leading brands have global operations which serve the food & beverage, power and energy and industrial markets. These businesses are recognized for best practices in manufacturing, strategic sales channels, broad product lines and aftermarket support services. SPX’s comprehensive portfolio of processing equipment, patented features and research and development efforts continue to produce groundbreaking technologies in the Food and Beverage industry. Look to SPX Flow Technology for: • Positive Displacement Pumps • Centrifugal Pumps • Heat Exchangers • Homogenizers • Valves • Fittings • Systems

Contact: 262-728-1900 or 800-252-5200 www.spxft.co

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Südmo North America Inc. As part of the Norit Group, Südmo North America Inc. delivers innovative aseptic and hygienic products and solutions to the dairy, food, and beverage industries. Südmo North America is the single source supplier of all Norit’s process technologies in North America. Along with our affiliate companies we integrate our collective knowhow, components, systems, and services, into tailored solutions for our partners. We know that sustainable and innovative products and services are the key to customer satisfaction. Norit Südmo is constantly expanding its extensive range of sanitary and aseptic valves and fittings with groundbreaking product designs. Recent innovations have provided longer maintenance intervals resulting in reduced plant downtime for aseptic processors, continuous operation with for dairy plants, and enhanced control technology for flexible process control. Norit Haffmans develops and manufactures a competitive range of components, systems, and solutions for brewers, beverage producers, wineries, and distilleries including quality control and CO2 recovery systems. We offer custom made solutions based on your quality and operational requirements and Norit Haffmans’ Total CO2 Management philosophy.

Taylor Products Taylor Products offers a broad range of modular packaging components engineered to perform alone or as a totally integrated packaging process system. With a weight range from 2 ounces to 2 tons and a material range that includes free-flowing granules to fragile powders we have the experience and equipment to provide the right solution for your application. Taylor Products manufactures a wide range of electronic valve bag packers that can be readily adapted to handle a variety of dry materials. To insure a positive valve bag seal, Taylor Products introduced TRUSeal, incorporating the latest ultrasonic sealing technology. Taylor Products manufactures a variety of open mouth bagging solutions. Their offering includes eleven different models all designed to handle different types of materials with accuracy and efficiency. Taylor’s bulk weighing and discharging equipment are engineered for a variety of materials. The modular design allows complete flexibility from a freestanding manual operation to a fully integrated and automated system. Taylor Products is committed to providing consumers with innovative packaging solutions. This drive led Taylor to its latest innovation: robotics. While many industrial companies utilize robotics, Taylor Products is leading the way in the packaging industry. This includes robotic bag placing and palletizing.

Norit X-Flow is a leader in the development and supply of innovative membrane technology to the global industrial markets. Norit´s X-Flow’s ultrafiltration membranes for the anaerobic MBR system are a sustainable solution for industrial wastewater. The system produces valuable biogas and high quality water for reuse or discharge. These are all part of Norit’s Clean Process Technologies – world class consumables, components and standardized systems – that provide greater process efficiency, longer lifecycles and cost savings, all of which ensures a more sustainable operation.

Contact: Südmo North America, Inc 1330 Anvil Dr. Rockford, IL 61115 815-639-0322 [email protected] www.norit.com

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Contact: Gary Saunders V.P. Sales and Marketing 2205 Jothi Avenue Parsons, KS 67357 Phone: 888-882-9567 Email: [email protected]

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

T.D. Sawvel Co.

Thermo Scientific

Have you checked out T.D. Sawvel lately?

Thermo Scientific product inspection solutions help our customers protect their brands by ensuring the quality and safety of their products.

You’ll ﬁnd that our new models are the best way to move your business forward. Highlights include: • Our Model 135 MPD “two-up” high speed cup ﬁller is designed for ﬁlling frozen desserts at speeds up to 120 cpm in sizes from 3-32 oz. • The fully-automatic Model 80 is one of our most versatile machines, providing a highly ﬂexible platform for makers of ice cream and other frozen desserts. Designed for container sizes from 3-64 oz., tooling is now available for ﬁlling square-round shapes.

For more than 50 years, we’ve earned a reputation for delivering reliable solutions through our application knowledge, equipment performance and unmatched customer care. Around the world, Thermo Scientific X-ray inspection systems provide complete protection from metal, glass, stone and other dense foreign objects. Our x-ray systems inspect packaged, bulk or piped product. For protection against metal contaminants, Thermo Scientific metal detection systems provide a high level of performance, ease of use and reliability—typically achieving up to 20% better sensitivity than competitive units. And to ensure you get the right system for your application, we offer hundreds of standard head styles plus custom

Whether you are dosing 1 ounce or 6 gallons at a time, T.D. Sawvel Co., Inc. provides effective automated solutions for denesting, ﬁlling, sealing, and capping a wide range of packaging shapes. Founded in 1976 with an early focus on automation for the ice cream industry, T.D. Sawvel’s dedication to supplying high quality solutions has led us to continually expand across many types of food products plus limited industrial applications.

apertures and systems. To ensure the accuracy for your weighing applications, Thermo Scientific checkweighers combine the latest in weighing technology with a variety of weighframes that include general purpose to more

We look forward to ﬁlling your needs.

demanding, high-rate and highaccuracy systems. When you need to “see what’s inside the pipe,” Thermo Scientific E scan™ in-line analyzer measures fat, moisture and protein in pumped food products, ensuring product quality to customer’s standards and saving on raw material costs, as well and saving time, money and energy. For more information about Thermo Scientific products and services please visit us at www.thermoscientific.com/productinspection, or call 1-800-227-8891.

With thousands of systems installed around the world, we deliver reliable solutions through our application knowledge, equipment performance and unmatched customer care.

Contact: Troy Sawvel, President T.D. Sawvel Co., Inc. 5775 Hwy. 12 West, Maple Plain, MN 55359 1-877-488-1816 toll-free www.tdsawvel.com

Contact: Thermo Scientific www.thermoscientific.com/productinspection 1-800-227-8891

www.foodengineeringmag.com | Food Engineering | January 2011

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GEA Tuchenhagen

Ultrachem Omnilube® Food Grade Lubricants

North America GEA Tuchenhagen is a global leader in the manufacturing of a wide range of sanitary flow components for the dairy, food, beverage, brewing and pharmaceutical industries – including mixproof, single-seat, divert, modulating, butterfly, pressure relief and sample valves; valve control technology; inline instrumentation; product recovery systems; cleaning devices and cleaning systems.

Product Recovery Unit

The Omnilube® family of lubricants from Ultrachem, Inc. is a complete line of premium quality food grade synthetic oils and greases for incidental food contact. Ultrachem manufactures these lubricants for compressor, hydraulic, chain, gear and multipurpose applications, and they are well suited for all food, beverage, pharmaceutical and related industries.

Our components are flexible so they can be adjusted to optimize process parameters and enable high productivity, efficient operation and a constantly high product quality. This is why we are one of the world’s leading manufacturers of process components.

In April 2007, in perhaps the greatest breakthrough in US dairy plant design in over 25 years, GEA Tuchenhagen’s 24/7 PMO Valve (FDA memorandum M-b-353) became the first mixproof valve to be authorized by the US regulatory authorities to allow seat cleaning while product is present in the valve. This means that US dairy plants no longer have to shut down production for two to three hours per day and can now reap the financial benefits of full 24/7 production. Overnight this valve changed the way US dairy plants are designed and operated. This innovation was followed up by the 24/7 PMO Tank Valve (FDA memorandum M-b-359), also the first of its kind to be authorized for 24/7 production in dairy plants.

Omnilube® synthetic food grade lubricants are specially designed to give you: • reduced lubrication intervals • longer equipment life • less downtime • reduced maintenance costs Ultrachem’s Omnilube® fluids are formulated with excellent anti-wear protection and oxidative stability, qualities that have been shown to surpass other food grade products on the market and outperform many non-food grade lubricants in food processing applications. With the Omnilube® line of premium food grade synthetics and white oils, performance is no longer sacrificed when converting to food grade products.

Mixproof valve

Additional services offered by GEA Tuchenhagen include concept design engineering, manifold prefabrication, plant service and customer training. In partnership with a nationwide distribution network, spare parts are often available overnight or same day in the US and Canada.

Founded in 1931, GEA Tuchenhagen began with building and overhauling dairies. This business segment rapidly developed into the engineering and manufacturing of key components such as valves, pumps, milk pasteurizers and other products. Contact: GEA Tuchenhagen North America 90 Evergreen Drive, Portland, ME 04103 USA Tel: 866-531-5629 Fax: 207-878-7914 [email protected] www.tuchenhagen.us

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January 2011 | Food Engineering | www.foodengineeringmag.com

Omnilube® food grade products meet all of the requirements of the USDA and FDA H-1 regulations, 21 CFR 178.3570, and conform to the requirements of NSF. They are also approved by the Orthodox Union for Kosher use.

Contact: Glenn Krasley Sales & Marketing Director Ultrachem, Inc. 302-325-9880 – office 302-521-4709 – mobile 302-325-0335 – fax [email protected] www.ultracheminc.com

PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Urschel

Vac-U-Max

Urschel Introduces New Model CC-DL Cheese Shredder and New Grating Options The new Urschel Model CC-DL Cheese Shredder offers the same dependable, overall operating principle as the industry standard Model CC-D, but with a larger 32 inch cutting zone enclosure. The larger enclosure promotes a smoother product flow with a larger discharge area, so higher capacities are achieved, and product build-up issues are diminished. The current CC-D enclosure measures approximately 22.8 inches in diameter. The new Model CC-DL comes standard with a powerful 10 horsepower motor and swing-away feed hopper to simplify cutting head changeovers. “The CC-DL Shredder offers many positive features, Urschel is pleased to be able to build on the existing brand. While we are proud to introduce this new machine, Urschel is also selling part kits to our present CC-D customers. These kits allow customers to increase the diameter of their CC-D cutting zone enclosure for greater efficiency. These new developments present opportunities to our customers looking into new equipment, as well as adding more flexibility for existing Urschel CC-D owners,” stated Tim O’Brien, vice president of sales at Urschel. The CC-DL Cheese Shredder offers a wide variety of slices, shreds, newly available grating options, and strip cuts. The versatile machine features easily interchangeable cutting heads enabling switchover of heads in a matter of minutes. Specially designed knives are inexpensive to replace and do not require sharpening. Through new Urschel engineering developments, Urschel now offers a wide variety of grating heads that offer cuts from coarse granules to different types of shreds. Grating heads present added flexibility to slicer/shredder Models CC, CC-D, CC-DL, and CCX-D. Grating heads incorporate a simple design of four posts with corresponding fasteners, upper support ring, locking lower support ring, and a grating screen. A multitude of interchangeable grating screens are available to easily switch from one style to another. Applications include cheese, coconut, nuts, and carrots. “The Model CC series of machines continues to grow. We offer several different types of CC slicer/shredders to suit different applications. New grating head options significantly increase existing cutting capabilities,” stated Tim O’Brien, vice president of sales at Urschel. Urschel offers complete Product Test Cutting Facilities throughout the world. Product Test Cutting Facilities feature extensive, complete analysis by experienced technicians to determine the best Urschel machine suited for each application, and assist customers in discovering additional cutting options.

VAC-U-MAX specializes in design and manufacture of pneumatic systems and support equipment for conveying, weighing and batching of dry materials. The primary technology for conveying is vacuum, but positive pressure pneumatic systems as well as mechanical conveyors are used as applications dictate. An equally important activity is design and manufacture of heavy duty industrial vacuum cleaners, ranging from small air and electric powered drum styled units to large electric and diesel powered units.

Contact: Urschel Laboratories, Inc. PO Box 2200, 2503 Calumet Avenue, Valparaiso, IN 46384-2200 U.S.A. E-mail: [email protected] Phone: (219) 464-4811 www.urschel.com

Markets Served VAC-U-MAX equipment and systems are sold worldwide. Major markets for conveying systems include the chemical, food and pharmaceutical industries. Specialty applications include conveying of small parts and objects, including coins and heavy metal powders.

Technologies A pioneer in vacuum pneumatic conveying, VAC-U-MAX has had many firsts, including air-powered venturi power units, direct-loading of vacuum-tolerant process equipment and vertical-wall “Tube Hopper” material receivers. A UL-listed designer and manufacturer of control panels, VAC-U-MAX furnishes integrated control systems that provide coordination of material movement, batching, and processing, with tie in capabilities to existing control systems.

Major Products Pneumatic Conveying Systems • Dilute Phase Vacuum Conveying Systems • Dense Phase Vacuum Conveying Systems • Dilute Phase Positive Pressure Conveying Systems • Dense Phase Positive Pressure Systems • Multi-ingredient Handling • Batch Weighing Systems • Bulk Bag Unloading • Bulk Bag Loading • Bag Dump Stations • Gravity Diverter Valves • Aero-Mechanical Conveyors • Flexible Screw Conveyors

Pneumatic Conveying Systems

Industrial Vacuum Cleaning Equipment • Air Operated Drum Top Vacuum Cleaners • Electric Drum Top Vacuum Cleaners • Continuous Duty Portable Electric Vacuum Cleaners • Central Vacuum Cleaning Systems • Hose, Tools, and Accessories • Tubing, Couplings, and Fittings

Aero-Mechanical Conveyors

Flexible Screw Conveyors

www.vac-u-max.com

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PACK EXPO, INT’L DAIRY SHOW & IBIE SHOW PORTRAITS AND IPE SHOW PREVIEWS ADVERTISEMENT

Volkmann, Inc.

Wire Belt Company of America

Volkmann, a market leader in vacuum conveying, designs and manufactures high quality, high performance vacuum conveying systems, used by manufacturers throughout the globe for the transport of fine food particles, chemicals, granules, pellets, tablets and small components in lean, dense or plug flow conditions.

Since 1947, Wire Belt Company of America has proudly maintained a reputation for developing advanced conveyor and belting solutions to meet the automated processing needs of the food industry. Wire Belt is a fourth-generation family owned company, dedicated to serving our customer base and remaining the industry leader in stainless steel conveyor belt innovation. Wire Belt continues to raise the bar on customer support, satisfaction and on-time delivery! In 2008, Wire Belt’s on-time to promised ship date was 99.93%! CONVEYOR BELTS Wire Belt continues to outperform the competition in product innovations and new technologies. Wire Belt’s CompactGrid conveyor belt is engineered specifically to replace heavier balanced weave belts, and difficult to clean plastic modular belts. Engineered with 70% open surface area, Wire Belt’s USDA Accepted CompactGrid conveyor belt provides optimal performance in processes where product coating, drainage, and liquid or air circulation are factors. Wire Belt’s entire line of belting products are accepted by the USDA NSF/ ANSI/3-A hygiene standards. This is the only acceptance that can assure you that you have the cleanest, safest conveyor belt available. CONVEYORS Wire Belt also offers CarrySmart® conveyors, its unique made to order line of sanitary conveyors. The CarrySmart line includes Flex-Turn, Straight, Shuttle, and Spreader or Converger conveyors. CarrySmart conveyors are custom designed to accommodate your specific processing application. Other advantages include open construction that is easy-to-clean, gentle product handling, and one of the tightest transfer and smallest turning radius available.

Suitable for the food, pharmaceutical, nutraceutical, and chemical industries, Volkmann conveyors are built reflecting a design philosophy that makes the use of Volkmann equipment intuitive and simple to apply, and operate. Simple to use. Simple to clean. Simple to maintain. Simple to install. Volkmann conveyors feature product transfer that is dust-tight, segregation-free and damage-free. Conveying can be to, or from, bag opening, mixers, blenders and packing machines etc. Modular in design they are ideal for frequent clean downs and, by using common size seals and clamps throughout, operators do not need intensive training in order to carry out everyday operations. With features such as “No-Tools” disassembly and easy cleaning, as well as designs conforming to cGMP standards, the Volkmann range is industry leading with the additional benefit of air driven Multijector vacuum generation and ATEX certification for explosion- proof applications. Volkmann also offers a unique “No-Tip Unloader” for transfer from drums, barrels or bins to any process, a NEW MX range of vacuum pumps and unique QX filter designs and “Rip & Tip” bag dump stations, Bulk Bag Unloaders and additional powder handling equipment.

Contact: VOLKMANN, Inc. Hainesport Business Complex 3855 Sylon Blvd., Hainesport, NJ 08036 Phone: 609-265-0101 Fax: 609-265-0110 eMail: [email protected] www.volkmannUSA.com

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Contact: Wire Belt Company of America 154 Harvey Road Londonderry, NH 03053 Phone: 603-644-2500 Fax: 603-644-3600 E-mail: [email protected] www.wirebelt.com

See us at the IPE Show Booth # 4966

CLASSIFIEDMARKETPLACE AUCTION

EMPLOYMENT

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TO SUMMIT YOUR RESUME OR SEARCH, PLEASE CONTACT: STEVE GREEN MANAGING DIRECTOR, THE JUDGE GROUP (610) 617-1647 PHONE * [email protected]

WWW.JUDGEINC.COM Spectrum Group/USA Food Jobs 727-461-4868 “The Placement Company for Food Industry Professionals” Since 1978 we have been successfully assisting people in enhancing their careers in the Food Processing Industry. We specialize in all aspects of Food Manufacturing Employment including Operations, Production, Engineering, Maintenance, Distribution, Food Safety, Quality Assurance, and R&D management.

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When you are considering a change of employment give us a call. Our promise to you is professional and honest service. Contact us by e-mail: [email protected] Our Website: www.usafoodjobs.com Phone: 727-461-4868 s!TTNArnie Holder

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Call CXR COMPANY • Warsaw, IN 800-817-5763 • fax 574-269-7140 www.cxrcompany.com www.foodengineeringmag.com | Food Engineering | January 2011

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EQUIPMENT FOR SALE

AUCTION

AUCTION ALERT Nebraska Meats 124-132 Malvern Street, Newark, NJ Complete Smoked Turkey & Pork Further Processing Facility February 10th, 2011, 10:00 A.M. CST Live Onsite and for online bidding register at Bidspotter.com In conjunction with Loeb Winternitz, Great American Group and Branford Group

Complete information including inventory with pictures and Terms & Conditions is available online at www.barliantauctions.com, www.loebequipment.com and at www.bidspotter.com or please contact us at (630)553-6992 or email [email protected].

Inventory A 12% Buyer’s Premium will be added to all purchases with an additional 3% charged on all internet purchases.

Repak Mdl. RE20 Rollstock Vacuum Packager, 420 mm web width, 300 mm advance, w/Lytron Kodiak Recirculating Chiller I J White Spiral Freezer, 13 tiers of s.s. belting, 29 ½” W, 6” product spacing (2) Metalquimia Mdl. AVVistick-260/6000 S.S. Injectors Supervac Mdl. GK812B S.S, Vacuum Chamber Machine Supervac Mdl. ATI5D+E S.S. Hot Water Dip Tank Supervac Mdl. Bl15 S.S. Dryer, 34” W X 36” L (2) CVP Mdl. A300 Freshvac Dual Snorkel M.A.P. Vacuum Packager (6) Friedrich Smokehouses, gas ﬁred, (4) 5 truck & (2) 4 truck Alkar Smokehouse, natural gas ﬁred, 2 sections w/common wall, (18) trucks capacity/side, each section w/3 door pass through (2) Red Arrow Mdl. 100 Powr Smoker Liquid Smoke Applicators (7) Red Arrow Mdl. 100 Deluxe Powr Smokers Liquid Smoke Applicators (2) Red Arrow Mdl. 2000 Powr Drench Liquid Smoke Applicators Approx. (200) Smoke Trucks Approx. (1,400) Smoke Screens (3) Daniels Mdl. DFE2000 S.S. Vacuum Tumbler Treif Mdl. 1950 High Speed Slicer, s.s. w/Treif Puma-CE touch screen controls MTC Mdl. LEC S.S. Vat Dumper, 3,000 LB cap. Anco Mdl. 827C Slicer (10) Hobart Mdl. 5801 Band Saws

(4) Ulma Mdl. Superchik Stretch Film Overwrappers (6) Bizerba Mdl. GV Automatic WeighPrice-Scale Labeling Machines (4) Precision Automated Systems Weighing/Labeling Systems w/Mdl. WD1000 Label Printer (4) Universal Labeling Mdl. L60E Bottom Labeling Machine (4) Universal Labeling Mdl. L60E Top Labeling Machine Lantech Mdl. Q30 Pallet Wrapper Busch Mdl. RAO630.B42.61001 Vacuum Pump (1,302) Tote All 2000 Plastic Lugs w/lids Roser Mdl. 3706 Tote Washer FPEC Mdl. 327SL S.S. Frame Incline Conveyor Admix Mdl. Rotosolver S.S. Brine Mixer (13) S.S. Vats Alloy DAF System, 7’ W X 23’ L X 6’ D, 10 h.p. Philadelphia Mdl. 2300 HDCH Baler (2) Gardener-Denver Mdl. EBERGH Electra-Screw Rotary Air Compressor Gardener-Denver Mdl. RNC125A1 Compressed Air Dryer Gardener-Denver Mdl. EBH99G Rotary Screw Air Compressor (8) Hussmann Mdl. GAH66-410-A-PSCTIP Evaporators, 6 fan (7) Kramer Evaporators, (2) fan (7) Krack Evaporators, (4) 6 fan & (3) 4 fan Large Quantity Kramer, Russell, Bohn & Imeco Refrigeration Units

ONSITE / WEBCAST AUCTION TUESDAY, JAN. 25, 10 AM LOCAL By order of secured creditor, assets of Protein Solutions

Preview: Mon., Jan. 24th, from 8 AM - 4 PM Central

Auction & Preview Location: 4220 S Kildare Ave,Chicago,IL 60632

Assets of a Leading Chicago Meat Processing & Packaging Facility • (22) VACUUM PACKAGING MACHINES • (2) STAINLESS STEEL SLICERS • (2) STAINLESS STEEL MIXER/GRINDERS • STAINLESS STEEL SKINNER • (2) PRODUCT FORMERS • FROZEN BLOCK GRINDER • STAINLESS STEEL AUTO GRINDER

• VACUUM STUFFER • (6) STAINLESS STEEL INJECTORS • (4) S. S. 500-LB. VACUUM TUMBLERS • (3) S.S. NEEDLE TENDERIZERS • STAINLESS STEEL DICER • (3) S.S. SCAN PORTIONING MACHINES • (2) HYDRAULIC MEAT PRESSES

(15) STAINLESS STEEL METAL DETECTORS • CONVEYORS • (17) BAND SAWS (3) AIR COOLED ROTARY SCREW AIR COMPRESSORS • (5) CASE SEALERS • STRAPPING MACHINE LARGE QUANTITIES OF SUPPORT EQUIPMENT

Attention Original Equipment Manufacturers and Equipment Re-Builders N there Now th is i a better b tt alternative lt ti tto stainless steel or copper-nickel for meat and poultry processing equipment.

These are partial listings only. For more info. on additional auctions or to subscribe to our email/mailing lists, visit

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170

January 2011 | Food Engineering | www.foodengineeringmag.com

A Buyer’s Premium is in effect • IL License #444000215

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www.foodengineeringmag.com | Food Engineering | January 2011

173

AD INDEX

Untitled-1 1 COMPANY

PHONE NUMBER

PAGE

COMPANY

8/27/10 PHONE NUMBER

Admix Inc.

800-466-2369

99

Lubriplate Lubricants Co.

800-733-4755

68-69

Ashworth

800-682-4594

94

Ludeca Inc.

305-591-8935

40, 62

Marchant Schmidt Inc.

920-921-4760

16-19

Avure Technologies

www.responsetrack.net/secret5 122

Baldor Electric Company

888-828-4920

37, 87

Bete Fog Nozzle, Inc.

413-772-0846

105

Bimba

800-44-BIMBA

14, 81

Breddo Likwiﬁer

800-669-4092

139, IBC

Buhler Sortex Inc.

209-983-8400

Bunting Magnetics Co. Burkert Fluid Control Systems Burns & McDonnell Cablevey Conveyors

800-835-2526

56 36, 93

800-325-1405 816-822-3812

49 73, 121

641-673-8451

50

Charles Ross & Son Corp.

800-243-ROSS

27, 55

Clarion Lubricants

832-486-4375

9

DCI, Inc.

800-276-7599

64, 104

Demaco

321-952-6600

78

Douglas Machines

800-331-6870

ECO Bionics Eriez Magnetics

866-438-6136

125 1, 143

888-300-ERIEZ

29

Evergreen Packaging

319-399-3200

24, 132

Flexicon Coporation

888-353-9426

30, 89

Fortress Technology

888-220-8737

43

FPEC

479-751-9392

FPSA

703-761-2600

79, 145

Fristam Pumps

800-841-5001

7, 127

Gamajet

877-GAMAJET

136

GEA Techenhagen North America

866-531-5629

GEA Westfalia Separator Inc.

800-652-2532

Masosine Process Pumps

800-282-8823

Material Transfer & Storage

800-836-7068

MEPACO

920-356-9900

Midwestern Industries Inc.

52, 62 54, 116 26 59, 109

877-4-SIZING

44-45

MPE Group

800-965-6065

13

Munson Machinery

800-944-6644

46-47

NuTec

815-722-2800

38-39

888-82-OMEGA

2, 82

Omega Engineering Inc. Opto 22

800-321-6786

Pack EXPO

www.packexpo.com

Parker Hanniﬁn

BC 10-11

800-343-4048

Pro Mat 2011

117

800-446-2622

32-33

Quickdraft

330-477-4574

80

Reid Supply Company

800-253-0421

65

Reiser

781-821-1290

107, 137

Rexnord

262-376-4800

90, 134

Schenk Accurate

800-394-2941

58, 120

Siemens

usa.siemens.com/security

SlipNOT Metal Safety Flooring Smoot, Magnum Systems

66, 75

800-SLIPNOT

133

800-748-7000

60

Specialty Equipment

713-467-1818

88, 118

Spraying Systems Co.

800-95-SPRAY

51, 112

5, 119

SPX

www.spx.com

IFC, 61

6, 67

Sudmo North America Inc.

815-639-0322

115

800-813-6644

34, 106

Summit Industrial Products

800-749-5823

12, 48

Heat and Control, Inc.

800-227-5980

103, 129

T. D. Sawvel

877-488-1816

57

Hixson Inc. Industrial Magnetics, Inc. ITT Jabsco JAX JBT FoodTech Kason Corporation Key Technology

800-722-6622

101

Martin Brothers

Harpak

Hinds-Bock Corporation

877-292-5715

91

Taylor Products, Magnum Systems

www.hixson-inc.com

42

Thermo Scientiﬁc

800-227-8891

888-582-0821

4

Ultrachem, Inc.

302-325-9880

41

978-281-0440

85

Vac-U-Max

800-822-8629

25

800-782-8850

22

Volkman, Inc.

609-265-0101

53

www.jbtfoodtech.com

96-97

Wilden Pump

909-422-1730

108, 128

973-467-8140

52, 64

Wire Belt Company of America

509-529-2161

20, 131

Woodward & Curran

888-882-9567

January 2011 | Food Engineering | www.foodengineeringmag.com

92 63, 135

603-644-2500

35

www.woodwardcurran.com/fe

23

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.

174

10:23 AM PAGE

ENGINEERING R&D Kevin T. Higgins, Senior Editor

First-ballot inductee

`

The Packaging Hall of Fame Class of 2010 includes professionals from a number of walks of life but only one inventor: Bob Dodrill. Think of it as the packaging equivalent of the Motion Picture Academy’s Irving G. Thalberg Award for Lifetime Achievement: When selecting inductees, the Packaging Machinery Manufacturers Institute’s Hall of Fame panelists consider each nominee’s entire body of work. The yardstick for engineers includes not only inventions and technical achievements but also their contributions to the industry and their community. By those criteria, only one engineer made the cut in 2010: Robert K. Dodrill, chairman of Rollprint Packaging Products Inc. in suburban Chicago. A native of West Virginia, Bob Dodrill graduated from West Virginia University in 1962 with a degree in chemical engineering. He joined DuPont Corp., working primarily with food companies and their packaging suppliers. Rollprint’s roots were in printing, but Dodrill guided its conversion to a supplier of flexible packaging for the then-nascent medical packaging field. His first innovation was the foil header pouch, an enclosure with a breathable panel to allow sterilization with ethylene oxide prior to venting and sealing. A clear version followed, enabling surgeons to gauge the size of

` Robert K. Dodrill, chairman, Rollprint Packaging Products Inc., Addison, IL

human bones and tissues for transplantation before opening the pouch and breaking sterility. Hall of Fame judges also were impressed with Dodrill’s contributions to food retorting, with one suggesting the military’s lightweight, zero-defect pouches for ready-to-eat meals would not have been possible without them. Dodrill is winding down his professional career, though he continues to work 12-hour days and attests to the enthusiasm he retains. His daughter (a chemical engineer) and son (a mechanical engineer) are assuming day-to-day responsibilities at Rollprint.

for medical. Rollprint was still primarily printing on FE: When did your involvement in packaging begin? rollstock and wasn’t doing any laminating and coatDodrill: After graduating from college, I went to ing. I saw the opportunity to add those capabilities work for DuPont, consulting with converters of packaging materials. Cellophane was king and had been since the 1920s, but cellophane is a very fuelintensive material. When polyethylene and OPP became available, I knew those materials would take over because of their cost advantages. One of the companies I consulted with was Rollprint. In the 1970s, 70 percent of Rollprint’s business was the cellophane used to wrap single-serve packages of Keebler crackers. The market for disposable medical devices started to develop in the early 1970s. I told several of my converter clients, “You might be interested in developing sterile packages for these devices.” They all said the market was too small, and I was out of my mind to think there was a future in flexible packaging

and bought into the company. Today, we only print to sell our lamination and sealant technology. FE: Why was the foil header pouch so successful? Dodrill: Ethylene oxide (ETO) is the only accept-

able way to sterilize sutures, and that presented a problem when absorbable autosutures were introduced. The package needs to provide a high moisture barrier, but it also has to be completely vented after treatment because ETO is a strong poison to humans. Our solution entailed two strips of film, with the sides joined by a peelable sealant and forming a chevron at one end. A breathable Tyvek panel is affixed to one strip at the other end. The panel allows ETO to enter the pouch and then be evacuated before the pouch is sealed and pinched off below it.

www.foodengineeringmag.com | Food Engineering | January 2011

175

ENGINEERING R&D ` A technician conducts a tensile strength test in the labs of Rollprint Packaging Products Inc. Standardized testing came about through the efforts of Rollprint’s Bob Dodrill.

The peelable sealant is critical in validating pouch integrity. It cohesively splits when opened. If a hair were present, a clear line would be visible on the film’s surface. That’s the final proof that a nurse looks for before handing surgical gloves, operating instruments and other materials to the surgeon. FE: How did you safeguard that intellectual property? Dodrill: We received a patent for the

header pouch, and we were five years into it when Continental Can came out with a similar package. Our lawyers sent them a cease-and-desist letter, and they said, “Sue us.” They had a lot of money and we didn’t, so we abandoned the patent. Since then, we’ve relied on proprietary processes and trade secrets. It’s been effective. We introduced our sealant technology for coated Tyvek at least 10 years ago, and no one else has figured out how to do it yet. FE: You still hold a 1994 patent for a process for retort sterilization using flexible packaging. Dodrill: We patented the technolo-

gy with the intent of giving it away to 176

customers. It was related to our work with Hisaka, a Japanese manufacturer of advanced retorts. We started Advanced Retort Systems with the intention of supplying Hisaka’s equipment to North American firms, but we were 20 years too soon. Major food manufacturers introduced shelf-stable entrées in flexible packaging in the early ‘90s, and they were disasters. The problem was that they simply were canned goods in lidded trays. They used steam or air–oversteam retorts, which produce stratified layers of air, a poor heat conductor and steam, which is a great conductor. That’s a problem for sealed pouches because of the lack of pressure equilibrium between the retort and the pouch, which can rupture or deform. We knew the problem could be overcome because I had seen Japanese technicians using Hisaka equipment do it. They put sensors inside the pouches and closely monitored pressure during come up and cool down. While they controlled pressure empirically, we did it scientifically by using the laws of thermodynamics. FE: What was the most complex equipment project you attempted? Dodrill: In 1995, we began concept

design and engineering work on a fivelayer coextrusion laminator/coater. It was commissioned in 1998 and may still be the only machine of its kind in the world. Besides extrusion coating and laminating conventional polyolefins and polyolefin copolymers, it can extrusion-coat polyester and copolyester resins. These coatings can be used as high-temperature sealants for retort, ovenable and microwave applications, providing both weld and peelable heat seals. They provide excellent chemical resistance and antiscalping properties. The equipment can mix up to 21 resins

January 2011 | Food Engineering | www.foodengineeringmag.com

and hold a tolerance of 0.25 percent variation in the resin blend. W hen we approached bankers for a $10 million development loan, they asked how large the market was for this capability. We couldn’t answer because the capability didn’t exist. It was an interesting negotiation. Only after demonstrating the company wouldn’t go under if the project failed did we get the loan. FE: You served five years on the Flexible Packaging Association’s board and were a founder of the Sterilization Packaging Manufacturers Council. What prompted the council’s creation? Dodrill: Eight firms representing about

80 percent of the medical packaging business in the US and 70 percent of the worldwide market are on the council. Testing requirements for seal integrity and other performance indicators are very stringent, and in the early 1990s, medical-supply customers were demanding different tests for the same attributes. Finally, we got together to establish standardized testing. That work has since been turned over to the American Society for Testing Materials. The eight founding members are well represented on the ASTM committee that focuses on flexible package converting. FE: Do you see much potential for high-performance sealants and laminates in food and beverage? Dodrill: There are thousands of food

applications in Japan for our products, though relatively few here. Part of the problem is that people look at the individual components of flexible packaging, which makes our films look much more expensive than foil. But with the exception of Hershey Kisses, foil is always laminated onto another material and requires adhesives, in which case our low-end solutions often are cheaper. We developed stick packaging for inhalation therapy, and that technology is beginning to transfer to foods requiring a strong moisture and oxygen barrier. So I started in food, went to medical, and now I’m coming back to food. ❖

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