EXCLUSIVE REPORT: TRACK & TRACE SYSTEMS DELIVER MULTIFUNCTIONAL SOLUTIONS June 2011
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FEATURES
Plant construction projects (2006-2010) 700
COVER STORY
Annual Plant Construction Survey 600
613
Multifunctionality Delivered
94
100
27
Track & trace systems can do more than satisfy regulators; they can improve products, operations and relationships with customers and consumers.
0 New
91
2010
253
200
87
303 360 300 318 345
2009 300
146 145
Need-to-know manufacturing concepts and professional contacts kept food professionals engaged during the annual Food Engineering conference.
2007 2008
400
203
Food Automation & Manufacturing Conference Report
195
79
506
500
Year 2006
Tech Update: Energy-Efficient Refrigeration
Exp./Ren.
Total
60 40 50
Projects surge slightly as processors find value to be gained in upgrading existing facilities.
495 464 490
48
DC/Whse.
New, expansions/renovations and distribution centers/warehouses Total = New + Exp./Ren. DC/Whse. category includes both new and expansions, but only projects dedicated to distribution and warehousing (no processing).
There’s no complacency when it comes to driving down operating costs for food companies’ refrigeration systems.
Source: Food Engineering.
50 DEPARTMENTS 8
Editor’s Note
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Calendar of Events
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Manufacturing News Food safety, economy dictate consumer food choices
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Food Packaging Susceptors and the safety challenge
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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
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FOOD ENGINEERING Volume 83, Issue 6 (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
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June 2011 | Food Engineering | www.foodengineeringmag.com
See Food Master, p. 64
EDITOR’S NOTE
Product quality: Strange coincidence or harbinger?
O Joyce Fassl, Editor in Chief e-mail:
[email protected]
K , Food Engineering readers, what’s going on out there? I am very surprised to report four food and beverage quality issues that occurred on consumer purchases I made in the past six weeks. This morning, I discovered a 12-can fridge pack of carbonated beverages I purchased at a major supermarket chain contained one empty can. A box of popsicles I purchased last week at Walmart displayed the normal nutrition panel, but the area that’s supposed to contain calories and nutritional percentages was blank. A box of crackers I purchased recently at Redner’s Warehouse Markets that normally has two sleeves of crackers contained only one sleeve. I found several pieces of empty foil material in the bottom of a package of chocolate foil-wrapped Easter eggs I brought at Genuardi’s in late April. I began to wonder if my recent thrifty shopping habits at the discount chains had anything to do with the errors. Then, I
noticed several non-food household items (paper towels for example) I purchased at a discount store seemed to have lower quality than the same brands I had purchased at Genuardi’s or CVS for years. My nonscientific research shows slightly more than half of the defective or lower-quality items came from a discount chain. Everyone knows Walmart would not allow subpar performance from its suppliers, and I doubt the other retailers would either. Of these four food or beverage items I purchased, three were made by processors on the world’s top 100 food and beverage companies list. Are budgets being stretched too thin? Are these companies short-staffed? Are operations moving too fast? Is operator performance a problem? Are processors sacrificing accuracy for the sake of food safety? After receiving decades of quality products from the food and beverage manufacturing industry, I have to wonder what is happening. I hope this is just a strange coincidence and not a harbinger of quality problems. What do you think? ❖
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
June 2011 | Food Engineering | www.foodengineeringmag.com
Alex Peele Director of Project Engineering Interstate Brands Corp.
Dan Sileo Vice President, Manufacturing Sunny Delight Beverages
Diane Wolf Global Vice President, Safety and Environmental Sustainability Kraft Foods
David Haase Vice President of Operations WILD Flavors
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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
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MANUFACTURING
`NEWS PLANT OPENINGS & EXPANSIONS
Food safety, economy dictate consumer food choices
After having announced construction of a new 50,000-sq.-ft. distribution center in South Bend, IN, McCormick, will expand its operations in the same location. An investment of $8 million will be used to move brands in-house from a copacking facility.
Kellogg Canada will spend $43 million (CD) on an additional Mini-Wheats production line in Belleville, Ontario. The facility is expected to be operational by the end of the year. Steven Roberts Original Desserts and Ticklebelly Desserts, manufacturers and distributors of frozen desserts, will open a new bakery in Pembroke, NC. The company plans to create 342 jobs and invest $4 million during the next five years.
Sensient Colors, located in St. Louis, MO, will add an aseptic packaging line. The investment follows a $16 million expansion, begun in April 2010. Pinnacle Foods will expand its operations in Darien, WI, adding 127 jobs. The total cost of the project is $39.4 million. Pinnacle Foods’ brands include Birds Eye vegetables, Duncan Hines baking mixes and frostings, Vlasic pickles, Log Cabin syrups and more.
JBS is completing the addition of a $25 million refrigerated warehouse at its pork processing plant in Marshalltown, IA.
C
onsumer confidence in food safety is the highest it’s been in seven years, according to a study from the Food Marketing Institute (FMI). According to the report, US Grocery Shopper Trends, 88 percent of shoppers are completely or somewhat confident in the safety of food at the supermarket. More than 90 percent of shoppers either strongly or somewhat believe their grocery stores are doing their part to ensure the food they eat is safe. Processors, however, don’t quite measure up. When asked where they believe food safety breaches occur, more than half of shoppers named food processing and manufacturing plants. However, when respondents were asked who is responsible for ensuring food safety, more than half (58 percent) of respondents said they are responsible for the safety of their food, up seven points from 2010. Next on the list are manufacturers and processors at 35 percent, followed by supermarkets and government agencies at 28 percent each, says the study.
` Consumer confidence in food safety has risen in five years, and grocery stores are generally more trusted than restaurants for having safe food. Source: Food Marketing Institute.
According to the report, consumers continue to be most comfortable with food grown in the US versus imported products. Shoppers who are either very or somewhat comfortable with US food safety numbered 97 percent. The survey found that 76 percent of men are comfortable with imported food from Latin and South America, while 58 percent of women feel comfortable with imported food from the same areas. The survey also found that younger consumers are much more comfortable with imported foods compared to shoppers aged 65 or older. While 2011 so far has been a year w i t h o u t many h i g h - p ro f i l e f o o d recalls, consumer confidence in food safety is greatly affected by recall activity, says the report. Today’s technology is making it easier for food manufacturers and retailers to communicate food recall announcements quickly to a broad audience.
www.foodengineeringmag.com | Food Engineering | June 2011
13
MANUFACTURING
`NEWS Besides food safety, healthy eating is another concern, and nutrition labeling programs are helping consumers make informed choices. However, only 29 percent of those surveyed consider themselves very knowledgeable in the area of nutrition, and nearly half (49 percent) say they are not expert in this area. Only
14
17 percent, however, admit they could use some help in understanding nutrition labeling information, says the study. An overwhelming 90 percent of those surveyed believe home-cooked meals are healthier and more affordable than restaurant meals. The vast majority of consumers (82 percent) say they are responsible
June 2011 | Food Engineering | www.foodengineeringmag.com
for ensuring the food they eat is nutritious. Others place the responsibility on food manufacturers and processors (48 percent), government agencies (30 percent) and supermarkets (29 percent). Rising fuel costs, higher commodity prices and increasing international market demand for food are pushing food prices higher and higher. While these costs directly affect processors, they are causing consumers to rethink purchases. As a result, the number of trips consumers make to buy groceries has dropped to an average of 1.69 trips per week, the lowest level in the 37-year history of the study. People shopping for groceries only once a week rose from 29 percent to 34 percent, and those shopping once every other week increased from 12 to 20 percent, according to the study. The study also found the majority of shoppers drive less than five miles to their primary store, but 60 percent do not shop for groceries nearest or most convenient to their home. Two-thirds say the one reason they bypass the closest store is to seek lower prices. Nine in 10 consumers visit a full-service supermarket at least once a month, while nearly 60 percent visit a supercenter once a month, followed by warehouse club stores (27 percent). Whether it’s the quest for healthier food or shorter distance, consumers continue to show strong support for locally grown products, with as many as four out of five saying they occasionally purchase these products. The definition of local is, however, is up for grabs, with almost an equal number of people saying it’s within state lines (44 percent) and those who say it’s a certain number of miles (41 percent). In spite of any inconveniences, consumers’ commitment to sustainability is still growing, especially with behaviors that require little consumer sacrifice. Compared to 2008, plastic recycling rose from 62 to 75 percent in 2011, paper from 63 to 74 percent and cans from 70 to 78 percent. For more information on the study, visit www.fmi.org. ❖
INDUSTRY & PEOPLE ConAgra Foods, Inc. made a proposal to Ralcorp Holdings, Inc. to acquire Ralcorp for $86 per share in cash, or approximately $4.9 billion plus the assumption of $2.5 billion in debt.
Santa Monica Seafood acquired the customer base, corporate name, inventory and other assets of Long Beach Sea-
food Co. Lawson Software, Inc. signed a
Cargill’s Wichita-based pork business completed a transaction to acquire a 21,500-acre hog production site near Dalhart, TX from the Premium Standard Farms LLC subsidiary of Smithfield
affiliate of Golden Gate Capital and Infor, in a transaction valued at approximately $2 billion.
definitive agreement to be acquired by GGC Software Holdings, Inc., an
Dale Morrison, president and CEO of McCain Foods Limited, announced the passing of G. Wallace F. McCain, cofounder of the company.
Foods, Inc. Steven Sterling is joining Kellogg Company as senior vice president, global supply chain, and will serve as a member of the company’s executive leadership team.
Dean Foods Company is actively seeking a buyer for its milk processing, selling, marketing and distribution business located in Waukesha, WI. The company agreed to sell the plant and related business as part of the March 29, 2011 settlement agreement reached with the US Department of Justice and the states of Wisconsin, Illinois and Michigan. The divestiture includes the 170,000-sq.-ft. fluid dairy processing facility and equipment, the Golden Guernsey and La Vaca Bonita brands, and other related assets.
Nestlé signed a partnership agreement taking a 60 percent stake in the Chinese food company Yinlu Foods Group. Yinlu’s chairman, Chen Qingyuan, will continue to lead the company in the new partnership. Kraft Foods opened a new $80 million manufacturing plant in Pernambuco, Brazil. The plant will produce chocolate and powdered beverages and start a biscuit line in 2012. SABMiller plc and Molson Coors Brewing Company announced the appointment of MillerCoors President and Chief Commercial Officer Tom Long as the company’s new chief executive officer following CEO Leo Kiely’s decision to retire.
See Food Master, p. 132 www.foodengineeringmag.com | Food Engineering | June 2011
15
MANUFACTURING
`NEWS REGULATORY WATCH Ads aimed at kids headed in the right direction A working group of four federal agencies – FTC, USDA, CDC and FDA – issued
a set of guidelines for food industry marketing and advertising products intended for children. Congress directed the working group to develop recommendations for the nutritional quality of food marketed to children and adolescents, ages 2 to 17. The group is now seeking public comment on the proposed guidelines.
The Grocery Manufacturers Association (GMA) says the industry is already headed in the direction suggested by the guidelines. The group pointed to research conducted by Georgetown Economic Services that shows the average number of food and beverage advertisements that children 2 to 11 viewed on children’s programming fell by 50 percent between 2004 and 2010. “In recent years, food and beverage companies have adopted strict nutrition standards that have fundamentally changed the advertising landscape,” says Pamela G. Bailey, president and CEO of GMA. “Since 2005, there has been a significant decrease in overall food and beverage advertising on children’s programs, coupled with a dramatic increase in ads featuring healthier product choices and healthy lifestyle messages. These changes would not have taken place without the leadership and commitment demonstrated by America’s food and beverage companies.” FTC Chairman Jon Leibow itz acknowledged the progress leading food companies had made in promoting healthier foods to kids, but said more needs to be done. “We all have more work to do before we can tip the scales to a healthier generation of children,” Leibowitz states. “This proposal encourages all food marketers to expand voluntary efforts to reduce kids’ waistlines.” GMA says that, in recent years, food and beverage manufacturers have changed the recipes of more than 20,000 products to reduce calories, sodium, sugar and fat.
Dairy industry aims to fulfill NAFTA The long-running dispute between the US and Mexico over the use of Mexican delivery trucks on US highways could be near an end. At least, the dair y industr y hopes it is. A Department of Transportation proposal is aimed at addressing safety 16
June 2011 | Food Engineering | www.foodengineeringmag.com
concerns and US compliance with trade obligations to Mexico that will allow the two countries to fulfill their respective obligations under the Nor th American Free Trade Agreement (NAFTA). The International Dairy Foods Association (IDFA) welcomed the proposal, saying the dispute has cut into US cheese exports to Mexico. “This is an important step toward a solution that will put an end to the retaliation against our industr y ’s products,” says Clay Hough, IDFA senior group vice president and general counsel. “Not only will this resolve a long-standing dispute, but the agreement will send a clear signal to trading partners that the United States is serious about the reciprocal fulfillment of trade obligations.” Mexico is the biggest importer of US Dairy products, but IDFA says exports of cheese have fallen sharply after Mexico targeted the product with retaliatory tariffs. The current dispute began in 2009 when Congress passed an appropriations bill that eliminated the funding for the previous cross-border trucking pilot program with Mexico. “ We urge Congress to support a permanent resolution of this issue, which is important to maintain a critical market for US dairy exports,” says Hough.
and Vegetable, and Summer Food Service programs. The rule is par t of the Healthy, H u n g e r - Fr e e K i d s A c t o f 2 0 1 0 signed into law by President Obama and one of the key prov i sions to bol ster far m-to - school programs across the country.
“This rule is an important milestone that will help ensure that our children have access to fresh produce and other agricultural products,” says Agriculture Under Secretary Kevin Concannon. “It will also give a muchneeded boost to local farmers and agricultural producers.” ❖
Locally grown foods for school lunches USDA announced that its chi ld nutrition programs are implementing new rules designed to encourage use of local farm products in school meals. The final rule, published in the Federal Register, will let schools and other providers give preference to unprocessed locally grown and locally raised agricultural products as they purchase food for the National School Lunch, School Break fast , Spec ial Mi l k , Child and Adult Care, Fresh Fruit www.foodengineeringmag.com | Food Engineering | June 2011
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FOOD PACKAGING Kevin T. Higgins, Senior Editor
Susceptors and the safety challenge
`
With the microwave supplanting the convection oven, package engineers eye susceptor systems to better protect frozen-food consumers from undercooked products.
M
ore than nine in 10 US homes are equipped with a microwave oven, a saturation level that greatly enhances the convenience of frozen foods. That category is experiencing uneven growth but positive results where microwave product and package innovation have been strong, according to Mintel International Group Ltd., which pegs sales of frozen pizzas, entrées and snacks at $12.5 billion. But uneven heating and the limited temperatures achieved by home microwaves can pose a public health risk, particularly when the ingredients in a microwavable meal are partially cooked or blanched. In the wake of 2007’s Salmonella outbreak linked to turkey and chicken pot pies that sickened more than 400, frozen-food marketers added explicit cooking directions, including a recommendation to use a food thermometer when microwaving to verify temperatures reach 165°F.
` Freezer abuse that can warp susceptor patches is overcome in containers of Red Baron pizza singles, an advancement that netted Graphic Packaging International the technical award in food packaging from AIMCAL. Source: AIMCAL.
“It’s an impossible instruction,” frets Mark Etzel, associate professor in the Department of Chemical and Biological Engineering at the University of Wisconsin-Madison. Most Americans don’t know their microwave’s wattage, he observes, very few own a food thermometer, and “almost nobody obeys the standing-time” requirement. Admonishing people to “cook thoroughly” is a legal disclaimer that doesn’t address food safety, Etzel says. Without better food and package engineering, “it’s just a matter of time before there are [microbial] poisonings.” Crisping and browning are the main microwave benefits of susceptors, though their ability to increase temperatures by focusing electromagnetic energy and causing greater friction of charged molecules is a functional advantage. Fully metallized film produces one heat output and is prone to undercooking the center and overcooking the edges of food. Demetallized film reduces the likelihood of overcooking but results in less browning and relatively low heat. Printed susceptors are prone to runaway heating, though engineers at Inline Packaging Inc. believe they have overcome the problem by including a metallization layer that cracks at high temperatures, thereby limiting or preventing the phenomenon. “We’re designing the susceptor around the food,” says Jon Wolfe, application specialist at Princeton, MN-based Inline, allowing manufacturers to address a variety of quality and safety issues. “There is a food safety component to susceptors,” allows Bob Babich, GPI’s business development manager, with their ability to achieve 165°F kill temperatures an important benefit. But browning, crisping and removal of excess moisture remain their primary functions. ❖ For more information: Bob Babich, Graphic Packaging International, 770-313-7799,
[email protected] Jon Wolfe, Inline Packaging Inc., 763-360-0714,
[email protected]
www.foodengineeringmag.com | Food Engineering | June 2011
19
FOOD PACKAGING
The carbonattuned chicken
A
ll chickens are not created equal, even when they’re raised and processed by the same company. That’s why Gold’n Plump (GNP) Poultry recently added a value brand to a product line that already included a namesake chicken and a premium bird that sports the first carbon disclosure statement on a US chicken. Packages of Just Bare chicken from St. Cloud, MN-based GNP Co. bear a certification seal from the Carbon Trust, a not-for-profit created by the British government. Carbon Trust participants commit to reducing CO2 emissions through greater energy-efficiency and development of low-carbon technology. Just Bare is the second participating US food brand, following PepsiCo’s Quaker Oats. Lifecycle analysis determined the carbon footprint for various cuts of Just Bare, accounting for every input from feed grains to post-consumption waste disposal. A whole Just Bare chicken’s carbon allotment is 380g, according to Julie Berling, director-brand advocacy, while boneless skinless breast fillets clock in at 900g. Consumer research, including a 1,000-member customer panel, drove creation of Just Bare and the value-priced Sunny Roost brand, Berling says. A waste heat-recovery project at the firm’s
MECHATRON® 3-A Loss-In-Weight Feeders
` Gold’n Plump Poultry packages chickens at three price points, including its premium Just Bare brand, which touts its carbon consciousness with a certification seal from the Carbon Trust on the back of the container. Source: GNP Company.
recently expanded Arcadia, WI plant and a change in feed pellets to a more digestible shape that also reduces the mill’s energy inputs benefit all three brands, she notes, but sustainability claims are limited to the “less is more” Just Bare brand. Package integrity is important across the board, and three of five customers rate GNP’s package quality superior to competing products. “We’re continually trying to find materials that are sustainable but also meet production demands,” says Berling, though results have been mixed. A linerless label that does away with a release liner or peel-away backer was judged a modest improvement. On the other hand, a switch to clear PET trays for select products was prompted by recyclability, but Berling said few recycling centers actually accept them.❖
Quick, easy product changeover and food safety
SolidsFlow™ USDA Vibratory Feeders
With today’s stringent food safety standards and the need for greater process efficiency, having to disconnect up-stream hoppers and flex connectors to access a feeder during changeover or general maintenance doesn’t cut it. Neither does improperly designed components that trap material. Address those problems and other food safety related concerns with Schenck AccuRate’s non-process side disassembly and easy wash-down feeders. • OPERATOR FRIENDLY CONTROL PACKAGES FOR FEEDING AND WEIGHING SYSTEMS. • FIELDBUS, HMI, ACTIVE X, WIRELESS, AND GROUP CONTROLLER.
www.accuratefeeders.com PLEASE CALL: (800) 558-0184 OR (262) 473-2441 • E-MAIL:
[email protected] See Food Master, p. 3
20
June 2011 | Food Engineering | www.foodengineeringmag.com
Schenck AccuRate is a unit of Schenck Process
©2009 Schenck AccuRate
S U C C E S S
S T O R I E S
HOW A VEMAG DEPOSITOR
helped produce a H I G H E R Q U A L I T Y,
E X A C T- W E I G H T FILLED PRODUCT A TRUE STORY: A producer of premium Mexican foods had problems depositing fillings onto tortillas. Their piston depositor only worked if the fillings were soupy and flowed easily. However, they wanted to use thick, cold, chunky fillings to produce a more natural looking product. They also desired precisely portioned fillings with an exact weight and shape so that they could produce a consistent product. At this point, they turned to Reiser. The solution was our Vemag Depositor with a high-speed cutoff device and a sensor to automatically detect the tortilla as it was conveyed. The Vemag was able to transport the thick filling extremely gently while delivering exact-weight portions. As our customer grew and increased production, they looked at automated tortilla rolling and folding options. When they found their solution, Reiser engineers developed a high-speed depositing system to take full advantage of the increased capacity – without sacrificing quality or weight control.
T H E V E M AG WA S CHO S E N I N P L AC E O F T H E P I S T ON F I L L E R Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com
Leading the food industry in processing and packaging solutions.
FOOD PACKAGING
Standards by popular demand
Y
ears of preaching the advantages of open guidelines and definitions for automated packaging machines may finally be paying off for OMAC, the Organization for Machine Automation Control. Based on feedback from food manufacturers, the Ossid division of Pro Mach made PackML compliance a priority when engineering a new mid-range horizontal form/fill/seal machine designed to vacuum pack protein foods. A beta version of the machine, which operates in the 10-15 cycles a minute range, was introduced at the recent AMI International Meat, Poultry & Seafood show in Chicago. Named the Integrity, the machine will replace an older line inherited in an acquisition. In soliciting input from prospective customers, the preference for standardized controls and components, including universal parts, came through loud and clear, according to John Eklund, marketing director for Rocky Mount, NC-based Ossid. The machine is 3A compliant and is expected to meet USDA sanitary standards.
22
June 2011 | Food Engineering | www.foodengineeringmag.com
` Ossid’s Jason Angel demonstrates the ease-of-access to the sealing chamber on the company’s new horizontal form/fill/seal machine for protein products. The design of the 15-cycles-perminute vacuum machine was driven by meat packagers’ input, the OEM says.
Open controls are enhanced by the standardization of Bosch Rexroth automation components, he adds. Rockwell controls are an option. ❖ For more information: John Eklund, Pro Mach, 704-944-5340,
[email protected]
Packaging. Processing. Powerful.
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PERFORMANCE THROUGH ENGINEERING BETE HydroWhirl™ Orbitor
MaxiPass™ (MP) Nozzles from BETE
The XA Nozzle System from BETE
A New “Revolution” In Tank Cleaning BETE’s new HydroWhirl™ Orbitor is a versatile Clean-In-Place (CIP) rotating tank cleaning machine that combines high-impact cleaning efficiency with extended operating life, reduced life cycle costs and simple on-site service. The Orbitor can be completely stripped and rebuilt for maintenance ON-SITE in less than 15 minutes.
The ultimate in clog-resistance with the largest free passage available in a full cone nozzle Two unique s-shaped internal vanes allow free passage of particles equal to the orifice size, making the MP perfect for handling dirty, lumpy liquids. Pattern uniformity is exceptional, providing an even distribution throughout. Reliable spray under difficult conditions. Low flow model available.
Produces a no-drip or high-speed spray shut-off BETE’s low flow, air atomizing XA series nozzles provide very low flow rates. They are available in eight different spray patterns and numerous flow rates. The XA nozzles can be supplied with a number of hardware options to allow cleanout, shutoff of both. Hardware options are available in manual and pneumatic versions.
BETE is your strategic partner for engineered spraying solutions. Tank cleaning Mixing Coating Washing Drying Packaging
BETE HydroWhirl™ S A slotted rotating spray nozzle for quick, efficient tank cleaning The HydroWhirlTM S tank washing nozzle, with a 360° coverage, directs the cleaning water through a rotating head at the tip of the spray assembly. This spray pattern uses impact and repetition to quickly wash the tank which breaks up and removes contaminants. The low-maintenance, dual-bearing design, uses less water and lower pressure than static tank washers.
Twist & Dry™ Nozzles from BETE The Twist & Dry™ spray dry nozzle features the innovative thick swirl unit The robust design lasts longer, reducing dryer operating costs. The patented locking mechanism allows for quick and easy change-out and maintenance. BETE has expanded the range of the Twist & Dry™ series with the new TD-K, capable of operating at up to 10,000 psi.
BETE’s HydroWhirl tank cleaning nozzle
IN-HOUSE CAPABILITIES • 3D design, modeling, and measurement tools to create customized nozzle solutions • State-of-the-art spray laboratory to verify performance and supply detailed test results • Investment casting foundry for complete quality control and fast delivery • Specialized fabrication and welding expertise for multi-component assemblies PERFORMANCE THROUGH ENGINEERING Let our experience provide you with a recipe for success. www.bete.com
BETE Fog Nozzle,Inc.
BETE Fog Nozzle,Inc. BETE Fog Nozzle, Inc. 50 Greenfield St. Greenfield, MA 01301 T (413) 772-0846 F (413) 772-6729 www.bete.com
TECHNOLOGY S O U R C E B O O K
SWEEPER-SCRUBBERS Using hybrid drive or extended run-time battery-powered configurations, NilfiskAdvance CS7000 combination sweeper-scrubbers largely eliminate the hydraulic systems of traditional ride-on cleaning equipment. Operating with IP55 washdown-rated, electronically controlled electric drives and propulsion, the units utilize a cylindrical sweeping system and separate disc scrubbing system. Dedicated sweeping and scrubbing functions with one-pass cleaning power keep dry debris dry without introducing scrub solution into the debris hopper. Nilfisk-Advance, Inc.; 866-429-8175; www.advance-us.com
TUBULAR EVAPORATOR Used for the evaporation of low-viscosity items such as dairy products, fruit juices, plant extracts and other organic and non-organic products, the SPX falling film tubular evaporator consists of vertical tubular heat exchangers with a vapor separator, condenser and pumps. The unit provides a short residence time and high-efficiency heat transfer. Depending on the available energy source, either mechanical or thermal vapor recompression can be used in conjunction with the evaporator. SPX Flow Technology Systems, Inc.; 410-379-8556; www.spxft.com
PILOT-SCALE MIXER Suitable for pilot-scale or laboratory applications, the Silverson Verso bench-
top in-line mixer is controlled from a digital operating touch pad for reproducibility when scaling up. The 1hp unit has a self-pumping flow rate of 6.5 gal./min. (depending on product viscosity). It can be used with single- or multistage-rotor/ stator configurations. A range of interchangeable work heads is available for blending, emulsifying, homogenizing, solubilizing, suspending, dispersing, particle size reduction and reaction acceleration. Silverson Machines; 413-525-4825; www.silverson.com
SCREEN CUTTER Reducing hard, soft and fibrous materials into controlled particle sizes at high rates with minimal fines, the Munson Model SCC-15-B screen classifying cutter features a rotor design comprised of cutter heads attached to a helical array of staggered holders that continuously shear oversize materials against twin stationary bed knives. Carbide-tipped cutter heads positioned along the entire shaft cut materials into uniform pieces with little to no heat generation. Munson Machinery Company, Inc.; 800-944-6644; www.munsonmachinery.com
MIXING/BLENDING EQUIPMENT Ross offers hundreds of pieces mixing and blending equipment, from 1-qt. to 400-gal. capacities, for short- and long-term rental through its trial/rental program; mix vessels and auxiliary equipment, including vacuum pumps and heating units, can also be rented as a package along with any mixer or blender. Several laboratory models are available for free consignment. Charles Ross & Son Company; 800243-ROSS; www.mixers.com
www.foodengineeringmag.com | Food Engineering | June 2011
25
TECHNOLOGY S O U R C E B O O K
Best Pasta. Our ÀÌiÀÊ-iÀià produces superior artisan quality pasta and will last longer than any person’s career.
ÀÌiÀÊ-iÀiÃ: The Ultimate Pasta Machine Made Anywhere.
INVENTORY MANAGEMENT The BinMaster BinView inventory management system offers real-time bin level monitoring for solid materials via the Internet or a company LAN or VPN. The system’s sensors are programmed to take measurements at predetermined intervals and send bin level data to a gateway with connectivity to an IP network; the measurement data also can be stored and accessed exclusively on a company LAN or VPN. Alerts can be sent to a cell phone, PC or PDA via email when bin levels meet critical levels. The system offers a variety of configurations. BinMaster Level Controls; www.binmaster.com
DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934
trol panel that can be positioned in numerous directions. WeighPack Systems Inc.; 888-9344472; www.weighpack.com
defranciscimachine.com
[email protected] 321-952-6600
DISC PUMPS
F/F/S BAGGERS WeighPack XPdius Elite vertical, form, fill and seal baggers run at speeds up to 100cpm. The baggers open on both sides for access to all components inside the frame. The electronics and pneumatics are completely separated into designated panels. The top plate that covers the film and dancing bars has been removed to create an open top film path. The formers are held in place with 2 quick disconnect clamps instead of traditional bolts. Other features include tool-less removal of change parts and an articulating con-
See Food Master, p. 49
Featuring operational efficiencies for implementation in in-line continuous-formulation processes, Mouvex SLC Series eccentric disc pumps allow product ingredients to be fed, combined and mixed proportionally through a common manifold. The pumps accommodate wide changes in flow rates and viscosity, and are sealless, requiring no magnets, mechanical seals or packing. Other features include self-priming and line-stripping capabilities; dry-run operation for up to 10 min.; low shear rate; high vacuum and compression effect; reduced number of components; and cleanin-place/sanitize-in-place capabilities. All 3 SLC models have speeds up to 1,000rpm with flow rates from 4.4gpm (1m3/h) to 13.2gpm (3m3/h), and differential pressures from 87psi (6 bar) to 232psi (16 bar). Mouvex; www.mouvex.com
June 2011 | Food Engineering | www.foodengineeringmag.com
Providing Parts with the Perfect Fit UNIVERSAL CONNECTOR
FLOWMETER The Spirax Sarco TVA target variable area flowmeter is designed for use on saturated steam. The integral electronics unit removes the need for a differential pressure transmitter, impulse lines and additional equipment. A built-in temperature sensor provides full density compensation and enables power, energy, flow, total flow, pressure and temperature to be displayed. Spirax Sarco, Inc.; 803-714-2000; www.spiraxsarco.com
FOAM-BASED CLEANERS Designed for food manufacturing, dairy and brewery operations, Diversey Enduro Power high-performing, foambased cleaners improve penetration of dirt and soil, reducing the need for reapplication; their formula also makes them easier to rinse. EnduroChlor is a liquid, heavy-duty, extended contact, chlorinated alkaline cleaner. Enduro SMS is a soft metal-safe, extended contact chlorinated alkaline cleaner. Diversey Inc.; www.diversey.com
It’s never been easier. Genuine replacement parts from GEA Westfalia Separator are guaranteed to fit your requirement for optimal performance. Our extensive North American inventory means the right part is available and can be delivered to your facility overnight or, in some cases, the very same day. What’s more, our dedicated parts professionals provide technical service support for all the parts we deliver. To learn more about our replacement parts programs, including inventory management and specially developed service kits, contact Klaus Brinkrode at 201-784-4335 or email him at
[email protected].
Liquids to Value GEA Mechanical Equipment US, Inc.
GEA Westfalia Separator Division 100 Fairway Court · Northvale, NJ 07647 Phone: 201-767-3900 · Fax: 201-767-3901 Toll-Free: 800-722-6622 · 24-Hour Technical Help: 800-509-9299 www.wsus.com See Food Master, p. 65
1517
Constructed with 4-bolt technology and all stainless steel components, the Armstrong IS-4 universal connector for high-pressure and super-heat steam lines can withstand extreme heat and high-pressure environments. The connector is rated for Class 900 service and up to 1,245 psig at 900°F (86 bar at 482°C). It can replace steam traps in critical process applications without disturbing the existing piping. Armstrong International; www.armstronginternational.com
TECHNOLOGY S O U R C E B O O K
Clear. Safe. Solutions. Clarion provides the most highly refined white oils available to protect your facility from contamination, equipment failure, and downtime. EXPERIENCED
We have a 40-year history of processing white oils and continue to redefine the leading edge of industry innovation. SECURE
As an established national manufacturer, we know the importance of a strong supply chain: When you need our white oils, you’ll be able to get our white oils. COMPLETE
We’ve created one of the industry’s broadest lines of protective white oils; including Food Grade, Environmental, Technical, and Synthetic formulations. COMMITTED
Our technical field support team is able to optimize your operation by creating custom solutions.
COMPOSITE CAN
RELIABLE
Clarion food grade oils are NSF H-1 registered and Kosher certified. To learn how Clarion can refine your operation contact 855-MY-CLARION or visit clarionlubricants.com.
Used for instant drinks, soups, sauces, snacks, cookies, powdered milk and other oxygen-sensitive bulk food products, the Weidenhammer composite can has a peel-off top with an easy-to-open membrane and ring pull or flat tab; both versions ensure gas and oxygen impermeability. The composite can for milk powder products is produced in clean room conditions. Weidenhammer Packaging Group; www.weidenhammer.de remote monitoring and can be used for new construction or to upgrade old treatment plants to meet new regulations. It is compatible with any size tank. Biowater Technology; 401-305-3622; www.biowatertechnology.com
LOAD SENSOR
FoodGrade EnvironmentalGrade TechGrade SyntheticGrade
See Food Master, p. IFC 13, 36-41
WASTEWATER TREATMENT SYSTEM The Biowater MBBR/CMFF complete mix fixed-film wastewater treatment plant for food and beverage processing facilities optimizes treatment configurations to help clean-in-place and clean-out-of-place systems achieve compliance. A high-efficiency biofilm eliminates sludge return. Compact in size, the system provides
The Sensor Technology LoadSense intelligent load sensor can be integrated with a crane hook, forklift or other handling device for intelligent feedback of loading events. It can also be wirelessly integrated into a SCADA or manufacturing control system, enabling instant operating reports and customer billing. The sensor has an on-board single-chip computer for recording, analyzing and archiving readings, and wireless communications to transfer data in real time to a host computer. Saelig Company, Inc.; www.saelig.com
June 2011 | Food Engineering | www.foodengineeringmag.com
EVENTUALLY TIME RUNS OUT ON EVERYTHING. Environmental
Synthetic
Tech Grade
Contamination. Lost inventor y. Tighter margins. All just an equipment failure away. So safeguard your facility with Clarion Food Grade Lubricants. They offer the protection you deser ve and, with NSF H-1 registration and Kosher cer tification, the purity you demand. Our full line of food grade products is suppor ted by a rock-solid supply chain and 40 years of processing experience. To learn how the full line of Clarion Lubricants can provide superior performance and protection, contact 855-MY-CLARION or visit clarionlubricants.com
Food Grade
TECHNOLOGY S O U R C E B O O K
INSTANT FLOOR COATINGS Designed for food and beverage facilities where processing, handling, packaging and storage occur, DSM eco-friendly UVolve instant floor coatings have NSF registration for incidental food contact (NSF non-food compounds R2 category). Instant-cure solutions for the protection of concrete floors, the coatings have low odor and near-zero VOC emissions during installation. They can be applied even in cold temperatures. Royal DSM N.V.; www.dsm.com
SANITARY MIXER Suitable for liquids from 50 to 5,000 gal., the Sharpe all-stainless steel portable sanitary mixer creates a high flow with low shear and can be equipped with 3/4-, 1- and 1 1/4-in. diameter shafts in lengths up to 8 ft.; hydrofoil impellers from 4- to 16-in. diameter; and fractional to 2hp motors, either electric or pneumatic. Used for blending juices and adding ingredients to sauces such as meat or poultry, yogurts and a variety of other food products, the mixer is corrosion resistant and totally paint free. Sharpe Mixers; 800-862-3736; www. sharpemixers.com
BALL VALVE
See Food Master, p. 86
30
June 2011 | Food Engineering | www.foodengineeringmag.com
Engineered for gas, sewer and water applications where metal ball valves have typically been installed, the Asahi/ America PE100 ball valve features corrosion-resistant internal and external parts. Available in sizes from 1 to 6 ins., it has a 2-step planetary gear system and SDR11 spigot ends approved for maximum operating pressures of 230psi for water and 150psi for air or gas. Available in metric and IPS pipe sizes, the ball valve offers NBR seals for air or gas, and EPDM seals for fluids. It can be installed using butt, socket or electrofusion technologies. Asahi/America, Inc.; 877-24-ASAHI; www.asahi-america.com
TECHNOLOGY S O U R C E B O O K
TURBINE FLOW METER Suitable for water, hydrocarbon and cryogenic fluid applications, the COX LoFlo Series axial turbine flow meter has a repeatability of +/-0.25% of reading. Constructed of 316 stainless steel with -6 AN (MS) end-fittings, it employs a Si3N4 ceramic ball bearing system. The compact flow meter (2.21-in. face dimension) is not positionsensitive, and can be mounted in any piping orientation. COX Flow Measurement; www.coxflowmeasurement.com
OUR PRIORITY:
YOUR SAFET Y MATERIAL HANDLING ROBOT The ABB Robotics IRB 2600ID mid-sized integrated dress pack material handling robot has a 1.85m reach, 15kg payload, 26kg total upper armload, 337mm swing base radius and 511mm base width. A flexible conduit in its upper arm/wrist for routing cables and hoses for signals, air and power fully integrates process equipment with the robot. Suited for applications including case packing, carton handling, process tray handling, small format palletizing, plastic injection molding, machine tool tending and die cast machine tending, the robot can be mounted in multiple configurations and features a work envelope that extends well below its baseline. ABB Robotics; www.abb.com/robotics
SLIP RESISTANT METAL FLOORING PRODUCTS
ECO-FRIENDLY PRINTER The K-Sun Green Machine with MaxiLabel Pro Ver. 3.0 labeling software for Windows is an environmentally friendly label printer system for food processing operations that design and print professional pressure-sensitive labels in-house and on-demand. The label, heat-shrink tube and barcode thermal-transfer printer has a large, high-intensity backlit display for use in all lighting conditions. K-Sun Corporation; 800-622-6312; www.ksun.com
SlipNOT® Metal Safety Flooring
ASSE Booth # 1109
www.slipnot.com | 800-754-7668 www.foodengineeringmag.com | Food Engineering | June 2011
31
TECHNOLOGY S O U R C E B O O K
LINERLESS CLOSURES Portola Steri-Shield linerless plug closures for low- and high-acid aseptic beverage packages can be used for juices, isotonics, dairy, energy drinks, milk, vitamin waters, drinkable yogurt and teas. The lightweight closures are compressionmolded using a proprietary resin blend that includes highdensity polyethylene, and withstand an aseptic sterilization environment of up to 140ºF. The closures can be made in a variety of sizes ranging from 38 to 43mm, with or without a tamper-evident band. Portola Packaging, Inc.; www.portpack.com
TRAY FORMER
YES, YOU CAN:
Erecting corrugated trays with no glue, the Eagle POPLOK tray former is designed for any self-locking tray, including 1-tuck, 2-tuck, multi-tuck and more intricate display trays required by club stores. The former can erect multiple size trays on the same machine and run large or small trays, with or without a lid. The unit has sealed ball bearings, selfcleaning tracks in the blank transfer section, vacuum technology for tray extraction, top sheet-feed for positive tray control through the machine and a high-capacity lift table hopper. It can be interfaced with almost any packaging equipment and accommodates many different discharge heights. Eagle Packaging Machinery LLC; 305-622-4070; www.eaglepm.com
Sift, scalp oversize contaminants Sift, scalp, de-lump and and contain dust when dumping dewater, then remove internals manually with Bag Dump through hinged end cover, with Screening Stations Quick-Clean Centrifugal Screeners
INVENTORY MANAGEMENT SOFTWARE
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
Z-0695
CAN: 1 514 667 6777 UK: +44 (0)1782 597540 AUS: +61 (0)2 6043 1560
FastPic Systems FastPic5 inventory management and control software allows food processing and distribution facilities to track parts usage by cost center. Designed to manage manual and automated storage and retrieval systems, it can be configured to control single workstations and multiple work zones. The Standard Interface Protocol provides a link between host order entry systems and FastPic5 software, as well as many WMS and ERP systems. It is built on the Microsoft.Net technology platform. FastPic Systems; 800-897-8379; www.fastpicsystems.com
June 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
CONVEYOR GUARDS Martin Engineering EVO conveyor guards have component designs to restrict access to moving parts and pinch points. Standardized panels take a systematic approach to guarding; a variety of wedge bolts and bracket sizes suit a range of mounting options. Available in sizes from 11-in. x 17-in. samples up to 36-in. x 50-in. panels, the guards can be used in a variety of combinations. Conforming to OSHA 29 CFR 1910.217 when installed with a minimum of 5.5 in. of clearance between the guard opening and hazard, the guards also comply with MSHA Safety Standards 56.14107 (moving machine parts), 56.14110 (flying or falling material), 56.14112 (guard construction), 75.1722 (mechanical equipment guards) and 77.4400 (mechanical equipment guards). Martin Engineering; 309-852-2384; www.martin-eng.com
PROGRAMMABLE SAFETY CONTROLLER Designed to monitor specific machine inputs such as photoelectric sensors, light curtains, magnetically operated sensors, emergency stop buttons and safety mats, the elobau eloProg programmable safety controller allows users to program the function of these inputs using icon-based software to create specific logic to control the safety outputs. The modular safety system monitors and evaluates signals of machine safety applications on machines and in production facilities. The flexible configuration allows the inputs to be used for a range of functions. The base module can be combined in multiple configurations with other modules to extend the inputs or outputs. elobau sensor technology, Inc.; www.elobau-st.com
PET SHEET Targeted for clear, rigid thermoformed packaging for the food, dairy and consumer products markets, OCTAL DPET PET sheet is produced via a direct-to-sheet manufacturing process that bypasses several conventional manufacturing steps to create a product with high consistency and clarity. OCTAL Petrochemicals LLC FZC; www.octal.com
www.foodengineeringmag.com | Food Engineering | June 2011
See Food Master, p. IFC 14
Liquids to Value
)S 4ANK #LEANING (OLDING 5P 9OUR 0RODUCTION Now it doesn’t have to. We hear it a lot. Plant managers are under pressure to improve ENGCPKPIVKOGCPFGHƂEKGPE[TGFWEGYCVGTEQPUWORVKQPTGFWEG%+2 and produce as clean a product as possible. GEA Tuchenhagen can JGNR1WTUGNHENGCPKPI8#4+274'® orbital and rotating cleaners, intelligently designed with fewer parts and no mechanical bearings, feature strong mechanical spray patterns for the best cleaning results. Experience: r5JQTVGTENGCPVKOGOGCPKPIOQTGRTQFWEVKQPCPFNGUUYCVGTEQPUWORVKQP r$GVVGTENGCPKPITGUWNVUHQTCJKIJGTSWCNKV[RTQFWEVCPFKORTQXGFUJGNHNKHG r4GFWEGFEJGOKECNCPFYCVGTWUGHQTVJKURTQEGUU DGVVGTHQTVJGGPXKTQPOGPV Whatever your product, GEA Tuchenhagen has a cleaning solution HQT[QW%CNNVQFC[VQUGGJQY[QWECPDGPGƂV
GEA Mechanical Equipment
GEA Tuchenhagen North America %VERGREEN $RIVE s 0ORTLAND -% s 53! 4EL TOLL FREE s &AX INFO4.! GEAGROUPCOM s WWWTUCHENHAGENUS
TECHNOLOGY
Designed for large-run sealing of random case sizes, the EZ-Tek SB-2 EX random case taper utilizes pressure-sensitive tape and features a side belt drive, 12-gauge steel construction and powder coating. The unit automatically adjusts to operatorfed, random-sized boxes ranging from 4.5 in. to infinite box length; it also top- and bottom-seals cases ranging from 4.5- to 23-in. wide and 4.5- to 2- in. deep. The top and bottom tape heads are interchangeable. EZ-Tek Industries; 800-877-5658
overworking are eliminated because the product is neither rolled nor tumbled. Deposit sizes of up to 1 1/2-in. thick can be achieved; 45,000 deposits/hr. are attainable on certain models. NuTEC Manufacturing; 815-7222800; www.nutecmfg.com
CASE/LAYER PICKING SYSTEM
FILLING/PORTIONING DEPOSITORS Able to fit into existing production lines to deposit fillings for stuffed sandwiches, quesadillas, calzones, sandwich wraps, cordon bleu, burritos, egg rolls, hamburgers, meat pies, chicken Kiev and stuffed seafood shells, NuTEC C-frame filling/portioning depositors have a feed system that uses a rotating spiral to gently move product to the rotary vane pump. Bridging and
Intended for beverage operations, the RMT Robotics gantry-based case and layer picking system coordinates the activity of AS/RS, conveyor and multiple robotic gantries to systematically pick products in singles or groups and send them to the dock face in an optimized trailer load or palletizing sequence. The automated fulfillment system does not require fixed infrastructure like racking or shelving, and has a modular design that can be easily expanded. RMT Robotics; www.rmtrobotics.com
www.foodengineeringmag.com | Food Engineering | June 2011
nbe-inc.com/food
RANDOM CASE TAPER
Process-Specific, cGMP-Ready, FDA, 3-A, USDA Compliant Bulk Material Handling Systems
S O U R C E B O O K
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Save Energy. Save Money. Motorized equipment accounts for 64% of your plants electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow, or you can call in the Baldor Installed Base Evaluation Team and reduce your consumption fast. The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors and mechanical products, both in operation and from spare inventory. The IBE Team will produce
©2011 Baldor Electric Company
a comprehensive report and plan, targeting inefficient motors and mechanical drives with recommendations for immediate action as well as long-term strategies…all positively affecting your bottom line. If you’re ready to do something about your growing electricity consumption, email the Baldor IBE specialists at
[email protected] or call (864) 281-2100 to receive case studies with realworld savings. It’s an easy call with a big payoff. baldor.com
TECHNOLOGY S O U R C E B O O K
Process-Specific, cGMP-Ready, FDA, 3-A, USDA Compliant Systems View Material Handling Systems In Action
nbe-inc.com/food
COMPACT THERMOFORMER Just under 7-ft. long, the Multivac R 095 thermoformer is suitable for users with limited space and that are new to automated thermoform fill-seal packaging. All lifting and cutting functions are powered by electric drives instead of pneumatics; the need for cooling water has also been eliminated. The unit forms packages with a depth of up to 40mm with flexible design possibilities and modified atmosphere for extending fresh shelf life. Multivac, Inc.; 800-800-8552; www.multivac.com
Bulk Container Dumpers
status of a pump line, it has a weatherproof NEMA 4X (IP66) enclosure. OMEGA; 203-359-1660; www.omega.com
REPLACEMENT GAUGE GLASS
WIRELESS SYSTEM The Omega HPWS series of longrange wireless system simultaneously monitors and controls 4 switches or valves up to 8 miles away. Capable of supervising the fluid level in a tank, operation of a distant pump from a control station or monitoring the
Used in armored liquid level gauges and rectangular sight windows on boilers and process vessels in applications where level indication is required, L.J. Star Ilmadur I-420 replacement gauge glass is manufactured to mil spec. Made from a high-quality formula of borosilicate glass, it provides clarity, high-pressure capability and chemical- and thermal-shock resistance. The glass comes in 3 styles: reflex glass with grooves that make it easier to read water levels; grooveless, non-tinted transparent glass; and high-pressure glass with up to a 0.002 flatness tolerance. L.J. Star Incorporated; 330-4053040; www.ljstar.com
Bulk Bag Fillers
Bulk Bag Unloaders
nbe-inc.com/food www.foodengineeringmag.com | Food Engineering | June 2011
TECHNOLOGY S O U R C E B O O K
If you can only attend one trade show, this is it!
COMPACT SERVO MOTORS B&R 8LV servo motors are equipped with an absolute encoder system with a resolution of 262144 (=218) steps per revolution. Gear boxes are mounted directly on the motor; the center gear rests directly on the motor shaft and replaces the input shaft on the gear box. With the motors’ rigid structure and small amount of mass, high-performance control loops can be created for dynamic applications, even in tight spaces. A choice of gear boxes is available: the 8GM30 economy series, 8GM40 single- and 2-stage standard gear boxes and 8GM50 reinforced gear boxes with bearings optimized for radial and axial forces for mechanical compatibility with Wittenstein products. B&R Industrial Automation Corp.; www.br-automation.com moving linear slides, rams and pistons, injection molding machinery and moving mechanical sub-assemblies. Pinpoint Laser Systems; 800-7575383; www.pinlaser.com
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Engineered to evaluate and correct machinery alignment problems, the Pinpoint 4D Microgage receiver measures 2 linear axes X and Y and their 2 angular components’ yaw and pitch. The 2 linear axes show how well machinery is aligned along a common centerline; angular readouts show if parallelism problems are present. The 4-axis receiver operates over distances of 100 ft. or more and delivers a measuring precision of 0.0005 in. and 0.002º. It can be used for aligning lathes, turning centers, spindles,
Designed for sanitary applications, ACS Quick-Clean rotary airlock valves enable full validation access to the rotor and all internal surfaces of the housing without disassembly of the endplate. The valves have stainless steel housings that are CNC-machined to precise tolerances and internal surfaces polished to a No. 4 finish. They are available in 304 or 316 stainless steel, in sizes from 6 to 16 in., with pressure differentials up to 15 psig, and temperature tolerance up to 500ºF. Rotor configurations include closed-end, metering, shallow-pocket, Teflon-coated and adjustable-tip. Adjustable rotor tips are available in stainless steel, hardened steel or bronze. Interior surface coating options include hard chrome and Teflon. ACS Valves; 800-655-3447; acsvalves.com
©2011 FPSA
See Food Master, p. IFC 12
June 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
Product Delivered.
Just Right. PANEL GAUGE Designed for OEM panel applications, the Ashcroft Type 1001T commercial pressure panel gauge is available in dial diameters of 1 1/2-, 2-, 2 1/2- and 3 1/2-in. and in ranges to 6000psi. With a PowerFlex movement, True Zero indication and FlutterGuard protection, the ASME B40.100, Grade B steel case gauge resists the effects of shock, vibration and pulsation. Ashcroft; 800-328-8258; www.ashcroft.com plastic pallets, skids, slave, captive and special pallets or product bottom surfaces. A “green” solution, it requires no power, compressed air, brakes, reciprocating travelers or controls. Kornylak Corporation; 800-8375676; www.kornylak.com
DATA LOGGING METER
LIVE STORAGE SYSTEM Based on hysteresis control chemistry, the Kornylak Palletflo Freezer Wheel live storage system exhibits energy absorption for controlled speed operation over the entire temperature range of food freezer operations. It handles loads up to 4,000 lbs. on solid or slatted pallets with bottom boards either parallel to or across the flow direction; it can also handle pallets with cupped, warped, split, broken or missing boards. The system needs no slave or captive pallets, and operates with a range of standard wood, metal and
The Casella USA CEL-630 data logging meter measures workplace and environmental noise in environments prone to variable or fast-changing noise levels. By logging data of varying key noise levels at regular intervals over a run, the meter provides an overall average result along with a time history of every reading to help operators visualize how noise varied over the course of the measurement. It comes with a detachable microphone and preamplifier, allowing the meter to be placed in a safe place while the microphone is outside or in a dangerous industrial area. Pre-configured setups simplify measuring sound and ambient noise; all data is measured and stored simultaneously. Casella USA; www.casellausa.com
www.foodengineeringmag.com | Food Engineering | June 2011
Segregation Free. Damage Free. Abrasion Free. Dense Phase Vacuum Conveying. Safe, sanitary, easy to use, maintain and install, Volkmann high quality, vacuum conveying systems will deliver your product just right, no matter where it needs to go..
609-265-0101 www.volkmannUSA.com
TECHNOLOGY S O U R C E B O O K
ENCODER COUPLINGS Engineered for the precision feedback requirements of encoder applications, Zero-Max Control-Flex couplings feature a parallel linkage system that minimizes reaction forces due to unavoidable shaft misalignments. Designed with clamp-style zero backlash hubs, they have electrically insulating flex components with low weight and inertia. The couplings consist of 2 clamp-style hubs (to be attached to the system shafts) and a center flex member. The single-flex disc version of the couplings is designed for standard torque capacity; the 2-flex disc version is for increased torque capacity and torsional stiffness. The couplings can be used in packaging, machine tool, conveying and automated assembly systems. Zero-Max; www.zero-max.com
CERAMIC COATING EonCoat ceramic coating encapsulates porous substrates, providing waterproofing resilience on floors, walls and exteriors. The coating withstands water pressure of 4,500psi/310 bar and steam at 380°+F. It also resists abrasion, corrosion, chemicals and temperatures up to 1,250°F, and has a flame spread rating of zero. Completely VOC-free, the coating consists of 2 non-hazardous ingredients that do not interact until applied by a plural-component spray gun. It can be applied on surfaces from 35ºF to 200ºF. EonCoat LLC; 252-360-3110; www.eoncoat.com
There is nothing like a challenge to bring out the best ... With nearly 1700 hours of fresh thinking, clean design and total re-engineering, the Wenger Drying Technology team has met unprecedented design parameters. The result? Wenger’s all-new Enhanced Sanitary Dryer – featuring design innovations that: • increase sanitation • minimize cross-contamination risk • improve clean-out efficiency Get details now on this new standard in horizontal conveyor drying.
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See Food Master, p. IFC 32
40
June 2011 | Food Engineering | www.foodengineeringmag.com
[email protected] CHINA
TURKEY
TECHNOLOGY S O U R C E B O O K
For consistant food grade lubricant quality, buy from a company that is NSF H1 and ISO 21469 CERTIFIED.
STEP-MOTOR CONTROLLERS Unitronics Vision350 and Vision130 series all-in-one step-motor controllers have Pulse Train Output functionalities that support high-speed inputs up to 200kHz and high-speed outputs from 5Hz to 200kHz. Enabling users to implement up to 3 independent PTO instruction sets at one time, the controllers also allow creating and saving multiple speed profiles for precise step-motor control. Features include multiple auto-tuned PID loops, internal 120K data table for data logging and recipe programming, and SD card. Communication options include TCP/IP Ethernet, GSM/ SMS, MODBUS and CANopen networking plus remote access for data acquisition and program download. Unitronics Ltd.; 866-666-6033; www.unitronics.com
Summit Industrial Products is one of the fast growing synthetic food grade lubricant manufacturing companies in the US.
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www.foodengineeringmag.com | Food Engineering | June 2011
TECHNOLOGY S O U R C E B O O K
CIP SERVO PUMP FILLERS Hinds-Bock CIP servo pump fillers sanitize themselves; the front cover plates are hinged for rapid sanitation swab testing. Used with flowable products such as sauces, dressings, jellies, condiments and products with particulates like macaroni and cheese, the fillers can accommodate fettuccini Alfredo, fruit desserts with particulates and lasagna sauce with meat fillings. Operator fill adjustment is accomplished by calling up a recipe on the HMI panel. Hinds-Bock Corporation; 877-292-5715; www.hinds-bock.com
MEDIA REDUNDANCY CONTROLLER The WAGO 750-882 ETHERNET 2.0 media redundancy controller provides 2 redundant networks via independent ETHERNET interfaces. If redundancy is not required, networks are addressed separately for intra-network data exchange. The controller accommodates HTTP, BootP, DHCP, DNS and FTP. It includes 1MB program memory (program code), 512Kb data, 32Kb retain memory and 2MB Fast File System. WAGO Corporation; 800-346-7245; www.wago.us
Reimelt adds its world-renowned expertise to Zeppelin’s proud tradition of excellence A world leader in the design, manufacture, and supply of highly automated and integrated materials handling systems for powders and liquids, Reimelt systems are installed in world-class food and beverage companies around the globe. Continuous dough mixing/kneading technology, frying systems, and fermentation systems complete our vast offering of food manufacturing solutions. • • • •
Process Technology and System Development Automation Engineering Components, Service, & Support Codos® System for continuous process mixing & kneading
Growing stronger... to serve you better!
Tel: 813-920-7434 |
[email protected] | www.zeppelin-usa.com 42
June 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
WASHDOWN CURTAIN WALL
FILLING SYSTEM
Designed for manufacturers to isolate production lines for cleaning while operating at peak capacity on other lines, the ZONEWORKS SCW washdown curtain wall encloses areas to minimize overspray when cleaning and/or reduce the potential for cross-contamination during routine production processes. Constructed of cleanable 18-oz. white vinyl fabric, the curtain is intended for operations where compliance with federal food regulations is necessary. To reduce the potential for bacteria to accumulate, the curtain is manufactured without stitched seams, and is embedded with a proven antimicrobial agent. ZONEWORKS; 800-553-4834; www.zoneworks.com
The Dispense Works RingDex 100 filling system for filling/ capping operations is designed for low- to medium-volume production. The indexing ring is removable; the workstations feature quick-release tooling to accommodate different size bottles, vials, caps and tips. The system is pre-programmed allowing users to type values into an intuitive graphical chart, and then name the file. Typical parameters include fill volume, diving nozzle stroke, weight (to verify fill), capping torque and tipping stroke. Available in several configurations including a bench-top model, the system is network (LAN) accessible. Dispense Works Inc; 815-363-3524; www.dispenseworks.com
For over 70 years, Paul Mueller Company has earned distinction as an outstanding manufacturer of stainless steel tanks and industrial processing equipment. Mueller® has evolved into a global process solutions provider, offering manufactured equipment and components, integrated process systems, and expanded-scope construction. Mueller has the technical expertise, innovative engineering, and manufacturing resources to implement a process system specific to your needs. From modular systems to complete turnkey plants, when you think of process, think…
Mueller… your process solutions provider! Call us at 1-800-MUELLER or visit our Web site at www.muel.com!
©2011 Paul Mueller Company
See Food Master, p. 84
413
www.foodengineeringmag.com | Food Engineering | June 2011
43
TECHNOLOGY S O U R C E B O O K
BACTERIAL TESTING SYSTEM Used to determine aerobic bacterial counts in meat, poultry, seafood, dairy and produce, the MOCON GreenLight 910 bacterial testing system provides results within minutes or up to 8 hours, depending on the expected bacterial load. The unit provides an aerobic plate count or total viable count of a food sample’s microbial load by using a sensing assay or vial. As bacteria in the test sample multiply and respire, they consume oxygen. The change in oxygen is used to calculate the original sample’s colony forming units per gram for solids or per milliliter for liquids. Intended for food processing companies with low-to-medium throughput requirements, the system has a small bench-top footprint. MOCON, Inc.; www.mocon.com
MANUAL LIMIT SWITCHES
LABEL PRINTER
Hayward LHB Series manual limit switches are available in 2 sizes to fit all Hayward TB Series ball valves and through 8 in. of BY Series butterfly valves. Both sizes are available in a GF-PP housing with FPM seals and 304 stainless steel stem. Other features include a 20°F to 200°F temperature range, 2 adjustable SPDT 10 Amp @ 120 VAC switches, integral lockout and 1/2-in. conduit port. The switches meet ISO5211 and are CSA listed. Hayward Flow Control; 888-429-4635; www.haywardflowcontrol.com
The Tharo EASYLABEL 5 Platinum label printer has a collection of tools for FDA 21 CFR Part 11 compliance, including additional password and user options, logging options and format options. The printer’s GS1 barcode wizard makes creating GS1 barcodes a 4-step process. The unit supports Microsoft’s ActiveX Data Objects; its database editor uses Microsoft’s OLE DB for viewing and editing almost any database from inside the printer. Tharo Systems, Inc.; 800-878-6833; www.tharo.com
NEMO® Sanitary Open Hopper Pumps Flow rates up to 900 gpm Pressures up to 720 psi Sanitary and industrial designs available Semi-flowing to non-flowing products Good solids handling - low shear design FDA materials Replaces the need for conveyors
NETZSCH, the world market leader with 60 years of experience and over 500,000 progressing cavity pump installations worldwide. With sales, production and service on 6 continents ensuring customer support to provide
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44
June 2011 | Food Engineering | www.foodengineeringmag.com
NETZSCH Pumps North America, LLC Tel: 610-363-8010 email:
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Who can: leverage unmatched application experience to help you experience maximum feeding and pneumatic conveying performance?
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TECHNOLOGY S O U R C E B O O K
CANTILEVER STAND MOUNTS Supporting a conveyor from only one side, Dorner cantilever stand mounts open the other side up for easy access and belt changes. Engineered to work with Dorner 2200 and 3200 Series conveyors, the mounts come in widths between 2 and 24 in. Conveyors up to 6-in. wide are supported with a single cantilever bracket. Conveyors 8-in. and wider include a pivoting outboard support post. Dorner Manufacturing; www.dornerconveyors.com sure. Easily integrated into single item EOAT and manifolds, the pumps need only 1.2 or 1.4 in. of space and use standard compressed air logic, components and fittings. Maintenance-free, they can be supplied with a range of suspensions and suction cups ranging from 3/8 to 10 in. in diameter and are offered in a variety of materials including silicone. Anver Corporation; 800-654-3500; www.anver.com
SPEED REDUCER
VACUUM PUMPS Suitable for positioning close to the pickup point in high-speed pick-andplace systems, Anver VR Series Venturi vacuum pumps provide millisecond attach and release. They feature aluminum construction with brass inserts, have no moving parts and can pull a 26-in. Hg vacuum with 0.74 to 1.27 SCFM air flow and 72psi supply pres-
Eliminating oxidation concerns, the STOBER all-stainless steel K series speed reducer withstands harsh washdowns needed to meet the most stringent sanitation rules. IP69K certified, the unit tolerates extreme dust, contaminants and high-pressure washing and steam cleaning, and withstands caustic solutions used for severe washdown applications. STOBER Drives, Inc.; www.stober.com
www.foodengineeringmag.com | Food Engineering | June 2011
34th Annual Plant Construction Survey
Expansions & Renovations Rule
48
June 2011 | Food Engineering | www.foodengineeringmag.com
Projects surge slightly as processors find value to be gained in upgrading existing facilities. ` Wayne Labs, Senior Technical Editor
T
hough 2010 wasn’t the year for processors lacking reserve cash to find bank loans to f inance greenfield sites, fine-tuning and expanding existing facilities were certainly in vogue, according to Food Engineering’s 34th Annual Plant Construction Survey. To a certain extent, processors are finding expansion and renovations necessary to meet regulatory requirements and the demands of their customers—like Walmart and Costco, both of which have quality and traceability mandates in place. The survey table on pages 56 to 76 lists food and beverage plant projects underway, completed or in progress in calendar year 2010. While new plants were down ever so slightly from 2009 (0.7 percent or one project), expansions and renovations tracked upward at 8.5 percent (27 projects) compared to the previous year, showing some light at the end of the recessionary tunnel. Although 2010 was slightly better than 2009 in total projects (490 vs. 464), 2010 was still considerably below the 2007 banner year in plant construction that boasted 613 total projects. Plant projects dedicated to warehousing and distribution increased from 40 reported in 2009 to 50 in 2010, a 25 percent increase. This category did not track combined projects where both manufacturing and warehousing space were increased. These are indicated in the table by + D/W (plus distribution/warehousing). According to ZweigWhite, a research group that monitors architectural and engineering/construction (AE/C) firms, 2010 was a tough year for both processors and AE/C firms. However, a majority of AE/C principals are optimistic that business will pick up this year. According to ZweigWhite’s 2011 Principals, Partners
& Owners survey, 11 percent of those responding think business will be much better in 2011 than in 2010, and 57 percent said business will be somewhat better than last year. Looking abroad It’s no surprise that processors are taking on renovation and expansion projects to consolidate assets and make production operations more efficient, says Robert Hall, Haskell’s director of business development. Processors are also investing in cost-reduction projects and utility improvements to reduce operational costs. Hall believes the focus on capital expenditures (CAPEXs) can be attributed mostly to less demand in the marketplace (minimal volume growth) and greater investment in international capital projects. When it comes to international opportunities for US AE/Cs, principals are beginning to see projects abroad as a viable option, according to the ZweigWhite study. The survey indicated that 16 percent of AE/Cs are already doing international projects, and another 18 percent are looking favorably to international projects in the future. “Greenfield projects have been few and far between in the domestic market with the majority of greenfield activity occurring in the international markets— China, Russia and India tending to see more activity,” says Darryl Wernimont, POWER Engineers’ market specialist for food, beverage and consumer products. Besides the lack of CAPEX for greenfield projects, there is another factor contributing to the small number of startups, says Tyler Cundiff, manager of business development at Gray Construction. He points to the large number of greenfield sites built during the mid-2000s, which have provided necessary production capacity.
In t h e U S, s e v e r a l i s s u e s — t h e economy being the biggest—are driving renovations and upgrades. William Vaughn, VCP&A principal, sees overall economic fears hindering new construction, but fostering process upgrades and renovations. With the austere economic climate, processors expect more from AE/Cs. “Ten years ago ‘faster, safer, cheaper’ was a differentiator for many AE/C firms, today, [they are] still factors to a client, but no longer are differentiators,” says Wernimont. Schedule, safety and price are mandatory. The same holds true for green/LEED, bundled services and plant security. They are no longer a new trend or differentiator; they are expected, says Wernimont. “Today, if a firm is not abreast of sustainability, safety and plant security and doesn’t have the ability to bundle and manage a variety of services, it will have difficulty in meeting a client’s expectations,” he adds. Due to short product lifecycles and innovation in food products, processors have been compressing the time scale for the design and construction phases of a project, says Ian Howkins, SSOE Group’s senior project manager. Processors have a strong desire to meet market demands, but typically release capital spending on a “just-in-time” basis. According to Howkins, the same issues—efficiency, food safety and innovation—are driving projects, but with more intensity. There is a strong drive for increasing overall production efficiency—beyond the reduction of energy usage alone. Key considerations are reducing the time required for cleaning and changeovers; making production lines multifunctional; and minimizing idle equipment.
www.foodengineeringmag.com | Food Engineering | June 2011
49
CONSTRUCTION SURVEY
Plant construction projects (2006-2010) 700
613
600
495 464 490
506
500
Year 2006 2007 2008
400
253
2010
146 145
195
203
27
94
100
0 New
Exp./Ren.
Total
60 40 50
200
303
300
360 300 318 345
2009
DC/Whse.
New, expansions/renovations and distribution centers/warehouses Total = New + Exp./Ren. DC/Whse. category includes both new and expansions, but only projects dedicated to distribution and warehousing (no processing). Source: Food Engineering.
Green and safe “Quality-of-life” projects are driving processors to upgrade existing lines, and these projects are often considered by the public to be healthful and green, according to Ray Schieferecke, Burns & McDonnell’s director of food and consumer products construction. “There is a lot of emphasis on making [manufacturers’] products healthier, their production processes more efficient and their waste streams cleaner.” Processors are also paying more attention to Safe Quality Foods (SQF) criteria and food plant operating standards, says Robert Graham, vice president of food and consumer product for The Austin Company. Quality and food safety are actually being driven by “top-down” demands from end-users (customers), such as the retail chains and big-box stores, and competition from other processors touting safe and quality products, adds Graham. 50
Getting the highest-quality product out the door might be helped along by combining Six Sigma and lean manufacturing techniques, says Wernimont. Six Sigma initiatives seek to identify and remove causes of defects and errors in the manufacturing process. The lean initiative focuses on the reduction of waste and the increase of productivity. These techniques can be applied to flow processes, equipment performance, ergonomics and error prevention. Sustainability has multiple benefits, says Bob West of AM King Construction’s business development group. They can let consumers know about corporate responsibility, decrease energy costs, reduce a plant’s carbon footprint and are often rewarded by both federal and state governments with incentive programs. “There is a progressive, increasing focus on green initiatives, which will often result in tax savings/credits in addition to any
June 2011 | Food Engineering | www.foodengineeringmag.com
long-term reduction in energy costs,” says Howkins. But processors should remember that while green initiatives have an intangible factor for a project gaining corporate or public relations support, they can’t always be quantified by normal engineering criteria, he adds. The trend, however, is for companies to incorporate green initiatives into all aspects of their business—from renewable energy resources, reduced packaging and overall awareness of reducing their carbon footprint. Controlling allergens, managing food safety Whether a new site or a retrofit, protecting food from airborne contaminants and allergens is increasingly important to processors, says Karl Landgraf, project manager at The Dennis Group. Landgraf reports increased insistence on isolating cooked food from raw, allergens from non-allergens and open product from the environment. This can be facilitated through partitioning, good HVAC design (air pressurization and filtration levels) and personnel practices (e.g., gowning and air curtains). Joe Bove, Stellar’s vice president of design services, reports an increasing interest in hygienic zoning and filtration and separation, due to growing concerns about airborne contaminants and the management of allergens. He also reports an increase in compartmentalizing food processing activities, due to the increasing cost of space. When it comes to food safety, there is increased focus on self-performing audits, rather than relying on outside firms, for processors’ production facilities as well as their ingredient suppliers, says Howkins. Established manufacturers are looking at existing facilities and processes and making substantial investments to increase food safety by reducing the risk of microbiological contamination. Food safety and food security are two important reasons that Hendon & Redmond’s clients cite for renovations and expansions, says Jim Larva, project manager. Food safety and security have greater importance as processors are concerned with potential terrorism. New regulations
A Total Project Solution
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We see it clearly. Food & Consumer Products Caroline Cooper, 816-822-3831 www.burnsmcd.com/fcp
No Total Project Solution would be complete without a safe, reliable, efficient construction solution. Burns & McDonnell integrated design-build services: predictable project cost and schedule, single-point accountability. A successful outcome for you.
Engineering, Architecture, Construction, Environmental and Consulting Solutions "UMBOUBt$IJDBHPt%BMMBTt%FOWFSt%PIB 2BUBSt'PSU8PSUIt)PVTUPOt,BOTBT$JUZ .Pt.JOOFBQPMJT4U1BVMt/FX&OHMBOEt0SBOHF$PVOUZ $BMJGt1IPFOJYt4U-PVJT $ I B U U B O P P H B 5 F O O t , O P Y W J M M F 5 F O O t . J B N J t . J M X B V L F F t / F X : P S L t / P S G P M L ) B N Q U P O 3 P B E T 7 B t 0 ' B M M P O * M M t 0 N B I B / F C 1BMN#FBDI(BSEFOT 'MBt1IJMBEFMQIJBt3BMFJHI /$t4BO%JFHPt4BO'SBODJTDPt4FBUUMFt8BTIJOHUPO %$t8JDIJUB ,BO
CONSTRUCTION SURVEY
Innovation Efficiency
Packaging
Multifunctional lines Six Sigma
OEE
Niche market Healthy formulations
Lean mfg. Quick changeovers Minimize idle time
New markets FSMA
USDA 3-A
Codex HACCP
SQF
GFSI FDA
Food Safety are also driving the importance of food safety and security. For those building greenfield facilities, food safety is assumed, and quality management is a parallel requisite. “One of the primary trends in new plant design and construction is placing heavy focus on resources and technologies to enhance food safety and [its] general awareness,” says Gray’s Cundiff. There are definitely advances in building materials and equipment that help reduce the risk of food contamination, but there are other advancements with technologies to aid already sophisticated quality management systems, he adds. Contractor/ engineering quality management systems can now be more easily integrated with a processor’s food quality strategies to create a higher awareness and measurable/predictable results in plant construction projects, adds Cundiff. New regs Both the Global Food Safety Initiative (GFSI) and the Food Safety Modernization Act (FSMA) will no doubt help promote safe food for consumers, but many processors that follow HACCP and GMPs are already be in good shape. 52
The GFSI was written in 2000; The American Meat Institute (AMI) task force published guidelines for equipment in 2003, and for facility design in 2004, says Bove. Therefore, the industry has implemented better design practices in the areas of hygiene, allergen and species separation, temperature control and other preventive control measures. Design and construction firms are now more aware of the ongoing food safety requirements and compliance issues, adds Bove. Landgraf thinks FSMA will create a lot of talk and more studies, inspections and committees initially, but it is long overdue and can only benefit an industry still smarting from tainted peanut butter, dust explosions and frequent hamburger recalls. “The US will probably lag behind the rest of the world in adopting standards and enforcing them. On the other hand, many far-sighted US companies will embrace them and insist that their plants be ‘ahead of the regulatory curve,’” adds Landgraf. Meeting regulatory demands could mean shifting funds from other projects. Projects will be tailored to modernizing food and beverage plants to
June 2011 | Food Engineering | www.foodengineeringmag.com
` Processors find several reasons to start new projects: improve efficiency, be innovative with products and meet food safety regulations. But finding the right balance can be challenging. Source: Food Engineering.
comply with the new regulations, says Larva. This will decrease the number of plant additions and renovations. To ensure food is safe will require additional expenditures for some processors. On a practical level, says Haskell’s Hall, the ability to clean food processing equipment and the surrounding area becomes more critical. As manufacturing companies invest in their facilities, extra focus and attention will require upgrades to equipment, as well as to facility infrastructure. CIP systems will need to be more robust. According to Hixson’s Sander, delivering a quality, safe product is definitely at the forefront of the strategies of food and beverage producers; however, rather than the GFSI or regulatory changes, most recent safety improvements are being driven by customers such as Walmart, Costco and Kroger, whose club memberships and/or customer loyalty programs provide an unparalleled level of traceability that ratchets up accountability for suppliers. Furthermore, the desire to avoid the huge cost and negative publicity of a recall and the desire and benefits of being seen as the highest-quality provider are other reasons for food and beverage companies to manage/mitigate risk by improving food safety, adds Sander. While this regulatory discussion has centered on food safety, parts of the new regulations also include defense, and these will have an impact on most, if not all, food processors, says Robert J. Hope, senior physical security analyst with Burns & McDonnell. The impact to these entities can be broken down into three cost categories: 1. Identifying deficiencies in the current security posture of the facility and how the current security posture measures up to the expectations of the regulation
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CONSTRUCTION SURVEY
2. Identifying the measures needed to meet the expectations 3. The ongoing cost of developing, implementating and managing additional security policies, procedures and technology. Utilizing another federal program mandating security as a benchmark, Chemical Faci lit y Anti-Terror ism Standards (CFATS) developed by the Department of Homeland Security, a food processor can begin to understand the impact these regulations may have on its particular operation, both financially and culturally. Depending on the current security protocols in place, additional securit y improvements could increase the number of barriers between people (employees and guests or employees to employees) and the equipment and/or ingredients. This action alone can affect productivity by increasing the amount of time taken for an employee to conduct his or her daily tasks by having to pass through different levels of security, adds Hope. Saving energy By the end of this year, electrical rates will have been deregulated in most of the US. According to Hall, in many cases, the projects associated with energy reduc-
tion are economically justified on their own merit. For new sites and renovation projects, the LEED program offers many design standards that allow for reduced energy usage. Even when a processor is not pursuing actual LEED certification, the design principles can be leveraged at a minimal cost to the overall project, adds Hall. “Most of the companies we are working with have developed long-term targets for reduction of energy costs, so the impact of deregulation on its own is not a unique driving force,” says SSOE’s Howkins. However, many processors believe energy costs will continue to rise, and have now set lower hurdle rates for approval of energy-reduction projects. Examples of methods to curb electrical energy usage include: • Specification of higher-efficiency and variable speed motors • Consideration of variable frequency drives for more applications, e.g., ammonia and air compressors • Selection of energy-efficient lighting • Improved control of lighting for unoccupied spaces • Shutting down equipment when not in use • Monitoring peak loads, and shifting usage patterns if possible
• Monitoring and adjusting power factors when practical • Installing occupancy sensors in conference rooms and warehouses. Finally, Wernimont suggests the development of an energy plan/matrix or a thorough energy audit to understand where energy can be saved. In addition, some more active measures can be taken to convert wasted energy or create new energy, such as: • Integration of wind for electricity generation • Rooftop solar PV for electricity generation • Cogeneration for process heat and electricity • Waste heat recovery for electricity generation • Biomass conversion (e.g., waste to methane or fat/trims to oil). Food processors are facing challenges to upgrade their lines and equipment to be more efficient and save energy while meeting the demands of new food safety regulations. Processors that have always made food safety an integral part of their processes will find it easier to upgrade, innovate and compete while maintaining a responsible corporate image. ❖
The following companies assisted Food Engineering in compiling this survey: AM King Construction Bob West 704-365-3160 The Austin Company Robert Graham 770-330-4868 Big-D Construction Corp. Forrest McNabb 801-415-6030 Burns & McDonnell Ray Schieferecke 303-284-9935
54
The Dennis Group Karl Landgraf 413-787-1785 A. Epstein and Sons Noel Abbott 312-429-8048 Faithful + Gould Jonathan Marshall 612-338-3120
Gray Construction Tyler Cundiff 859-281-9255 Haskell Robert Hall 904-791-4798
Food Tech Mike Golden 781-261-9700
Hendon & Redmond Engineers/ Architects Jim Larva 513-641-0320
Gleeson Constructors LLC Harlan VandeZandschulp 712-258-9300
Hixson Bill Sander 513-241-1230
June 2011 | Food Engineering | www.foodengineeringmag.com
Middough Inc. James Bingham 630-756-7000 POWER Engineers Darryl Wernimont 904-318-7186 SSOE Ian Howkins 269-385-8618 Stellar Joe Bove 904-260-2900 VCP&A William Vaughn 770-938-2600
Imprecise water application on bread dough caused a significant QC problem for a leading bakery. Application of too much water caused the dough to rise unevenly while too little water resulted in the sesame seeds not sticking properly. In both cases, the baked bread had to be scrapped. PulsaJet® spray nozzles controlled by an AutoJet® Model 1550 Modular Spray System provided the precision required to ensure bread quality. The spray controller adjusts the flow rate of the nozzles based on line speed. The proper volume of water is applied uniformly even when conditions change. The hydraulic PulsaJet nozzles with positive shut-off prevent dripping, misting and overspray.
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CONSTRUCTION SURVEY Company
City
3g Processing
Mountain Grove
State MO
Primary Product
Type
Animal feed
Sq. ft. Cost (000) ($ Mil.)
New
A/E
Comp. Date
6
12/10
9 11
12/10 10/10 9/10 10/10 12/10 12/10 5/10 9/10 10 8/10 12/10 12/10 12/10 12/10 12/10 12/10 11/10 8/10 12/10 03/11 12/10 10 10 10 8/10 4/10 12/10 5/10 10/11 11 12/10
A Abbott Laboratories ADM Edible Bean Specialties Agro Farma Agroindustrias Unidades de Mexico Ajinomoto USA Alef Sausage Aliments Brookside Quebec Allen Family Foods Allen Foods Allens Inc. Alma Plantation, LLC Alpha Foods Co. Always Bagels, Inc. Amalgamated Sugar American Foods Group American Meat Company American Pasteurization Company American Popcorn Co. American Pulses Ltd. American Seafood Exchange, LLC American Sugar Refining Inc. Anheuser-Busch Anheuser-Busch Anheuser-Busch Archer Daniels Milling Company Arizona Canning Co. Arkat Animal Nutrition LLC Associated Brands Inc. Aurora Dairy Aurora Organic Dairy Azar Distilling
Campbell County Blumfield Twp. South Edmeston Bosq. de las Lomas Eddyville Mundelein Longueuil Harbeson Topeka Fort Worth Lakeland Waller Lebanon Nampa Sharonville Rockville Evansville Sioux City Shelby Boston Arabi Cartersville Moorehead St. Louis Columbus Tucson Dumas Etobicoke Platteville Platteville San Antonio
VA MI NY Mexico IA IL QC DE KS TX LA TX PA ID OH MO IN IA MT MA LA GA MN MO NE AZ AR ON CO CO TX
Nutritional formula Beans Greek yogurt refrigerated D/W Coffee Animal food Sausage/meat products + D/W Candy Poultry processing Baked goods Canned foods Sugar cane mill Frozen food products Bagels/bakery Sugar Meat Meat Contract pasteurization (HPP) Popcorn Vegetables Seafood + D/W Cane sugar Malted beverages Malt Malted beverages Flour milling Canned foods Dog and cat food Dry, packaged goods + D/W Fluid milk Dairy Vodka
Exp. New New New Exp. Exp. Exp. Exp. New New Exp. Exp. Exp. Exp. Exp. Exp. New Exp. Exp. New Exp. Exp. Ren. Ren. Exp. Exp. Exp. New Ren. Exp. New
8 152
87
135 200 115 60 15
14 35 3 1 The Austin Company 25 3 12 1 22 14 1
43
6
422
70 5
Food Tech LLC Middough Middough Middough
3 92 6 99 15
4
Hixson Hixson
3
B B. Lloyd’s Pecan Company B. Roberts Baldinger’s Bakery Barry Callebaut Bartlett Milling Company LP Basic Grain Products Baskin Robbins Beardy’s & Okemasis First Nation Beechnut Nutrition Corporation Bel USA Inc. Bell’s Brewery Inc. Birney’s Foods Blount Fine Foods Blue Bell Bluegrass Dairy and Food LLC Bongrain Cheese USA Boyd Station, LLC Bremner Inc. Brother & Sister Food Service Bruce Foods Bunge North America Inc.
Barwick Charlotte St. Paul Saint Hyacinthe Wilson’s Mills Coldwater Peterborough Duck Lake Town of Florida Leitchfield Comstock Berkeley Cnty. Fall River Fort Worth Glasgow City of Industry Danville Princeton Harrisburg New Iberia Destrehan
GA NC MN QC NC OH ON SK NY KY MI SC MA TX KY CA PA KY PA LA LA
Candy and nuts Ready-to-eat foods Bakery Cocoa Flour mill Rice cakes Ice cream Meat Baby food Cream, processed cheese Beer Barbeque sauce/pork Seafood Ice cream D/W Dehydrated dairy/non-dairy ing. Cheese processing Soybean meal, oil Cookies, crackers Canning, dried meats D/W Seasoning Soybeans D/W
Exp. Ren New Exp. Exp. Exp. Exp. New New Exp. Exp. New Exp. Exp. Exp. Exp Exp. Exp. Exp. Exp. Exp.
120 50 144
New
300
1 62 1 5 6
12/10 2/11 9/10 12/10 12/10 12/10 7/10 5/10 7/10 12/10 12/10 12/10 12/10 12/10 12/10 3/10 12/10 4/10 12/10 6/10 12/10
40
12/10
4 30 20 9 3
AM King
The Dennis Group 650 100
65 12
43
37 124 10 25
5 2
c Café Valley
56
Phoenix
AZ
Bakery
June 2011 | Food Engineering | www.foodengineeringmag.com
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CONSTRUCTION SURVEY Company
City
State
Calise & Sons Bakery Campbell Soup Campbell Soup Canada Bread Company, Ltd. Cargill Cargill Cargill Cargill Animal Nutrition Cargill Inc. Cargill Meat Solutions Cargill Meat Solutions Carolina Beer & Beverage Carroll Manufacturing & Sales Celestial Seasonings Central Garden Pet Chateau Chantal Chesapeake Gardens Chocmod Chocolove Christian Moerlein Brewing Co. Cincinnati Lab Supply City Brewing Company Clare Rose Inc. Clovervale Farms LLC Cobb Vantress Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Coca-Cola North America Colavita USA Columbus Salame Commonwealth Dairy ConAgra Foods ConAgra Foods ConAgra Foods ConAgra Foods ConAgra Foods ConAgra Foods ConAgra Foods Lamb Weston Constellation Brands Cooper Farms Corn Products Cott Beverage USA, Inc. Country Oven Bakery CP Ingredientes Crown One Corporation Crystal Lake Foods LLC Cuervo Culver Duck
Lincoln RI Everett WA Napoleon OH Hamilton ON Blair NE Gainsville GA Memphis TN Chambersburg PA Wichita KS Schuyler NE Waco TX Mooresville NC Avon OH Boulder CO Irwindale CA Peninsula Township MI Mount Carmel PA Saint-Jean-sur-Richelieu QC Boulder CO Cincinnati OH Forest Park OH Latrobe PA Shirley NY Amherst OH LaFayette TN Allentown PA Auburndale FL Auburndale FL Auburndale FL Auburndale FL Columbus OH Monmouth Junction NJ Northampton MA Shreveport LA Edison NJ San Francisco CA Brattleboro VT Decatur AL Fernley NV Kentwood MI Macon MO Milton PA Troy OH Delhi LA Canandaigua NY Van Wert OH Chicago IL Wilson NC Bowling Green KY Guadalajara Mexico Islip NY York NE Guadalajara, Jalisco Mexico Middlebury IN
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
C Bakery Soup Soup Frozen food bakery Grain Soybeans Corn Animal feed Soybeans Beef Turkey processing Brewery Spices Specialty teas Pet food Wine Soups Chocolate Nonchocolate confectionery Beer Animal food Beer Beer D/W Gelatin Chicken Soft drinks Beverages Beverages Beverages Beverages Soft drinks + D/W Soft drinks Beverages Soft drink D/W Olive oil Meat Yogurt Flour Dry seasonings, fruits, veg. Snack bars processing Frozen food/meats Canned foods Snacks Sweet potatoes Wine/alcoholic beverages Cooked meats Starch Bottled soft drinks Frozen dough Flavorings Food Meat Distillery Duck
New Ren. Exp. New Exp. Exp. Exp. New Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. New New New Exp. Exp. Exp. New Exp. New New Exp. Exp. Ren. Ren. Exp. New Exp. New New New New Exp. Exp. Exp. Exp. Exp. Exp. New Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp.
14 5 370
10
VCP&A
9/10 10/10 12/10 2/10 10 10 10 12/10 6/11 4/11 12/10 12/10 3/10 12/10 12/10 12/10 12/10 8/10 2/10 12/10 12/10 12/10 10/10 8/10 5/10 12/10 11 10 11 11 10/10 10/10 11 2/10 05/11 5/11 3/10 12/10 12/10 5/10 12/10 12/10 4/10 12/10 12/10 12/10 10 12/10 4/10 10/10 12/10 8/10 3/10 8/10
The Dennis Group The Dennis Group
12/10 5/10 4/10
The Dennis Group 22 100 Middough Middough Middough
90 75 3
64 3
8 15 Gleeson 3 6 5 Stellar
25
125
1 4 7 4 4 1 8
269
Gray Construction 3
92 250
VCP&A 120 Hixson Hixson Hixson Hixson 120
225 Hixson 118 60 40 17 225
380 75
50
10 3.1
Food Tech LLC Stellar
32 6 13 73 23 1 60 156 1 15 Middough
50 25
2 10 20 2 3
60
D Daddy Ray’s, Inc. Dairy Farmers of America Daisy Brand
58
Moscow Mills Schulenburg Casa Grande
MO TX AZ
Bakery Chip dips Sour cream
June 2011 | Food Engineering | www.foodengineeringmag.com
Exp. Exp. Exp.
76 130
17 40
<.05035365)>
$BO*SFBMMZTBWF NPOFZCZJOTUBMMJOH BTNBMMFSNPUPS 5IFUSVUI :PVKVTUNJHIUCFBCMFUP*GZPVMPPLBU ZPVSFOUJSFESJWFUSBJO ZPVMMQSPCBCMZmOEUIBUJGZPV SFQMBDFJOFö DJFOUDPNQPOFOUT XIJDIDBOXBTUF VQUPPGUIFFOFSHZUIFZVTF
ZPVMMCFBCMF UPJOTUBMMBOFX TNBMMFS IJHIFö DJFODZ%3NPUPS BOETUJMMHFUUIFQPXFSPVUQVUZPVOFFE "OE ZPVMMTBWFFOFSHZBUUIFTBNFUJNF CFDBVTF ZPVSDVSSFOUPWFSTJ[FENPUPSTNBZCFXBTUJOH FOFSHZUPPWFSDPNFUIFJOFö DJFODJFTPGZPVS FOUJSFESJWFUSBJO 4&8TOFX%3NPUPSTFSJFTJTTQFDJmDBMMZEFTJHOFE UPXPSLXJUIBUPUBMTZTUFN JODMVEJOHPVSIFMJDBM CFWFMHFBSCPYFTBOEFMFDUSPOJDESJWFT UPQSPWJEF ZPVXJUINBYJNVNFOFSHZTBWJOHT(FUUIF XIPMFTUPSZBOEMFBSOIPXUIF%3NPUPSTBSF UIFOFXFTUQJFDFPGUIFFOFSHZTBWJOHTQV[[MF BUTFXNPUPSUSVUIDPN
TFXNPUPSUSVUIDPN
CONSTRUCTION SURVEY Company
City
Dannon Company Dannon Company Dannon Company Dannon Company Daybrook Fisheries, Inc. De Wafelbakkers Dean Foods Dean Foods Dean Foods Dean Foods Dean Foods - Alta Dena Dean Foods - Heartland Farms DeBruce Grain Dennis Food Service DG Foods Diageo Diageo Diageo Diamond Foods Diamond Foods Diamond Pet Foods Diana’s Bananas Dominion Liquid Technologies LLC Domino’s Pizza Dorada Poultry DOT Foods Dreyer’s / Edy’s Grand Ice Cream, Inc. Dutch American Foods
Fort Worth Minster West Jordan West Jordan Empire McDonough Nashville Newport Orlando Spartanburg City of Industry City of Industry Decatur Bangor Gallman Plainfield Plainfield Plainfield Beloit Salem Ripon Chicago Cincinnati Grand Prairie Ponca City Mt. Sterling Fort Wayne Beecher
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
D TX OH UT UT LA GA TN KY FL SC CA CA AL ME MS IL IL IL WI OR CA IL OH TX OK IL IN IL
Yogurt Yogurt Yogurt Yogurt Fresh and frozen seafood Waffles Milk Fluid milk Fluid milk Fluid milk Dairy Dairy Grain handling, D/W Freezer Chicken Spirits Spirits Spirits Snacks Potato chips Dog food Frozen food Liquid foods Pizza dough Chicken Dry storage Ice cream Dry foods
Exp. Exp. Ren. Ren. Exp. New Exp. Exp. Exp. Exp. Ren./Exp. Ren./Exp. New Exp. Exp. Exp. Exp. Ren. Exp. Exp. New New New Exp. New Exp. Exp. Exp.
The Dennis Group 110 The Dennis Group The Dennis Group 92
3 28 11 The Dennis Group The Dennis Group The Dennis Group The Dennis Group The Dennis Group
93 150 18
1
90 2 3
1 1 8
Food Tech LLC The Dennis Group The Dennis Group The Dennis Group
340 25 1 100 90 138
Stellar The Dennis Group 4
12/10 12/10 4/11 6/11 12/10 4/10 12/10 6/10 11/10 3/11 6/12 6/13 12/10 10/11 12/10 12/10 11/10 4/10 12/10 8/10 12/10 5/10 12/10 12/10 12/10 3/11 6/10 4/10
E E.G. Emil & Sons Eaux Vives Water Inc. Embotelladoras Arca SAB Empire Foods Inc. Empire Specialty Cheese Enterprise Sugar Equity Group - Kentucky Division LLC Erie Meat Erie Meat Evolved Industries Evonik
Philadelphia St.-Mathieu-d’Harricana Culiacan Halifax Batavia Jeanerette Albany Listowel Mississauga New Roads Blair
PA QC Mexico NC NY LA KY ON ON LA NE
Deli products Water Coca-Cola bottling Fruits and vegetables Premium cheeses + D/W Refined sugar Poultry Meat Meat Prepared feed Amino acid
Ren. Exp. Exp. New New New Exp. New Ren. Exp. Exp.
14
35 40 125
23
Hendon & Redmond 2 28 3 5 130 1 40 5 3
The Dennis Group
The Dennis Group Middough
12/10 5/10 2/10 10/10 12/10 6/13 12/10 5/10 1/11 12/10 10
F Far Away Springs Farines SPB Meal Ltd. Farm Fresh Food Supplies, Inc. Farmers Rice Milling Company, Inc. FITCO Five Star Custom Foods Five Star Food Products Florida Flavors and Concentrates Fonterra Food Lion Foremost Farms Fort Recovery Equity Inc. Foster Poultry Farms FPL Food, LLC Fresh Express Fresh Mark Inc.
60
Brandonville Peterborough Amite Lake Charles Anniston Nashville Freeport Riviera Beach Shorewood Salisbury Appleton Fort Recovery Farmerville Lexington Harrisburg Massillon
PA ON LA LA AL TN NY FL IL NC WI OH LA SC PA OH
Bottled water Animal feed Produce, pickled-meat snacks Rice Chicken Frozen meat Deli products Beverages Dairy D/W Refrigeration D/W Cheese Egg D/W Poultry Beef Fresh foods Bacon
June 2011 | Food Engineering | www.foodengineeringmag.com
New 60 New New Exp. Exp. 12 Exp. Ren. 20 New 16 New 500 Ren./Exp. 100/2 Exp. 13 Exp. 25 Exp. Exp. Exp. Exp. 70
8 1 2 18 VCP&A The Dennis Group Hendon & Redmond 11 2 Stellar 47 1 9 9 Hixson 10
12/10 7/10 12/10 12/10 3/11 6/11 1/12 12/10 12/10 3/10 3/11 12/10 12/10 12/10 10 12/10
Your next project can be green. Let Alberici show you the way. We can combine our expert resources and process knowledge with industry leading LEED® practices to deliver your top of the line facility. And we’ll do it with time to spare.
www.alberici.com
Design-Build | Construction Management | General Contractor
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[email protected]
CONSTRUCTION SURVEY Company
City
State
Primary Product
Frito-Lay NA Frito-Lay NA
Dayville Topeka
CT KS
Snacks + D/W Snack foods
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
F Exp. Exp.
100
66 53
12/10 3/11
Animal feed Exp. Potato products New Yogurt Ren. Cereal Ren. Dough Exp. Cereal Exp. Yogurt Ren. Yogurt New Breakfast cereal Exp. English muffins Exp. Grain New Baby food Exp. Flavors and ingredients Exp. Flavors and ingredients Ren. Cheese Exp. Flat & pita bread, pizza crust + D/W New Bakery New Animal feeds New Deli meats New Peanuts and peanut products Exp. Ice cream Exp. Package distribution New Canned foods D/W New Ice cream New Frozen desserts New Grain ingredients Exp. Snack foods New Beer Exp. Meat Exp. Seafood Exp. Dips Ren. Mediterranean foods Exp. Beer Exp. Dairy Ren. Seafood + D/W Exp.
20 131
1
12/10 12/10 12/10 12/10 12/10 9/10 12/10 8/11 12/10 12/10 12/10 12/10 10 10 9/11 12/10 12/10 7/10 7/10 7/10 12/10 1/10 1/10 10 11/10 12/10 12/10 12/10 5/10 10/10 1/12 12/10 3/10 1/12 12/10
G Gatlin Feed Mill/Gatlin Corp. Gem State Processing/Oregon Potato General Mills General Mills General Mills General Mills General Mills General Mills General Mills Genesis Baking Co. Gerber Feed Service Gerber Products Givaudan Flavors Givaudan Flavors Glanbia Goglanian Bakeries, Inc. Gold Crust Baking Gold River Feed Products Golden Valley Farms Inc. Good Earth Peanut Co. Good Humor-Breyers Ice Cream (Unilever) Goya Foods Goya Foods Graeter’s Graeter’s Grain Millers Grand PaPa’s Snack Foods Great Lakes Brewing Co Great Lakes Specialty Meats/Qual. Meat Great Salt Lake Artemia Grecian Delight Grecian Delight Foods, Inc. Grupo Modelo Guggisberg Cheese Gulf Crown Seafood Co., Inc.
Gatlin Burley Carson Cedar Rapids Chanhassen Murfreesboro Murfreesboro Murfreesboro Sharonville Norwalk Dalton Fort Smith Cincinnati Florence Twin Falls Crest Hill Hyattsville Shelbyville Arthur Greensville Cnty. Sikeston Miami Pedricktown Cincinnati Bond Hill Eden Prairie Detroit Cleveland Mitchell Ogden Elk Grove Village Elk Grove Village Queretaro Millersburg Delcambre
MS ID CA IA MN TN TN TN OH OH OH AR OH KY ID IL MD TN ON VA MO FL NJ OH OH MN MI OH ON UT IL IL Mexico OH LA
Faithful+Gould Faithful+Gould 22 100 Faithful+Gould Faithful+Gould 20
24 200 89
335 204
45 8 1 2 Hixson Hixson The Dennis Group 31 7 7 12 1 7 1 Hixson
28 130
33 15 323 97
11 1 4 6 4 3
Big-D The Dennis Group
17 520 Hendon & Redmond 2
H H.T. Hackney Häagen Dazs Harris Teeter Hartz Mountain Corp. Harvest Time Bread Company Heaven Hill Distilleries Inc. HEB Hershey Hill’s Pet Nutrition Hilmar Cheese Company Holmes Cheese Co. Home Maide, Inc. Horizon Environment Technologies Hormel House of Raeford Farms of Louisiana Huy Fong Foods
62
Milton Tulare Greensboro Harland Twp. Mount Airy Bardstown San Antonio Hershey Emporia Dalhart Millersburg Harriman Saint-Prime Dubuque Arcadia Irwindale
FL CA NC OH NC KY TX PA KS TX OH NY QC IA LA CA
Dairy, snacks D/W Ice cream Perishable D/W Pet food Bread Distillery + D/W Bakery Chocolate D/W Pet food Cheese Cheese Arepas (breads, tortillas) Whey Meat Poultry Sauces
June 2011 | Food Engineering | www.foodengineeringmag.com
New Exp. Exp. Exp. Exp. Exp. Exp. Exp. New Exp. Exp. New Exp. New Exp. New
158 10 40 50 30 20
Stellar 4 3 4 4 Stellar
335 600
11 384 656
250 The Austin Company 100 3 2 1 89 2 40
8/10 9/10 9/10 12/10 7/10 8/10 9/11 12/10 12/10 12/10 12/10 12/10 5/10 3/10 12/10 12/10
Together, we can eliminate contamination and improve food safety. Balston Sterile Air Filters safeguard your operations from rust, pipescale, water, oil, and organisms usually found in compressed air. Balston Sterile Air Filters will remove contaminants at a very high effiency - up to 99.99% for 0.01 micron particles and droplets. Liquid releases from the filter cartridge to an automatic drain as rapidly as it enters the filters. This allows the filter to continue removing liquids for an unlimited time without loss of efficiency or flow capacity. The final stage of filtration removes all viable organisms with an efficiency rating of 99.9999+% at 0.01 micron. Select 1/4 to 1” line size filters are constructed of 304 stainless steel and are designed to hold up to the harshest environments.
www.balstonfilters.com
1 800 343 4048
CONSTRUCTION SURVEY Company
City
Icelandic USA, Inc. Imler’s Poultry Imperial Sugar Imperial Sugar Imperial Sugar Imperial Sugar Indiana Packers Corporation International Delights Interstate Warehousing Island Aespetics LLC Island Oasis Italian Home Bakery Ltd.
Newport News Altoona Gramercy Gramercy Port Wentworth Port Wentworth Delphi Clifton Franklin Byesville Buffalo Etobicoke
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
I VA PA LA LA GA GA IN NJ IN OH NY ON
Seafood Canned poultry D/W Sugar cane mill Sugar Refined sugar Granulated & liquid sugar Food Bakery Refrigerated warehouse Juice Beverage Bakery
Exp. Exp. New Ren. Ren. Ren./Exp. Exp. Ren./Exp. Exp. Exp. Ren. Exp.
88 108
New Exp. New Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Ren. Exp. Exp. Exp.
203 20 130
125 60 220 18 175 135 100 20
8 4 145 10 9 200 6
11 2 1
The Dennis Group The Dennis Group The Dennis Group Epstein Hendon & Redmond
Food Tech LLC
7/10 12/10 1/10 1/11 12/12 6/10 09/10 1/11 8/10 6/10 03/11 5/10
J Japan Food Corp. JBS USA JBS USA JBS USA JBS USA JBS USA Jel Sert Company Jerome Cheese Company JFC International Jim Beam Brands Co JM Smucker JM Smucker JM Smucker JM Smucker JM Smucker Folger Coffee Company JM Smucker Folger Coffee Company Joy Cone Co.
Linden Grand Island Marshalltown Plainwell Cactus Douglas West Chicago Jerome Hanover Park Clermont Orrville Scottsville Scottsville Scottsville New Orleans New Orleans Hermitage
NJ NE IA MI TX GA IL ID IL KY OH KY KY KY LA LA PA
Food Beef Pork Beef + D/W Beef Chicken Flavoring syrup/concentrate Mozzarella Seasonings + D/W Vodka, bourbon whiskey Jams, jellies, preserves, syrup Frozen products Frozen products Frozen baked goods Coffee Coffee and tea Bakery + D/W
Gleeson Gleeson 63
119 280
20 7 300 12 56 15
190
Gray Construction 30 5
3 152
7 5 72 21
The Dennis Group The Dennis Group The Dennis Group The Dennis Group
12/10 7/11 5/11 10/10 6/11 12/10 12/10 12/10 5/10 12/10 10/13 12/11 8/12 3/10 12/10 12/10 10/10
K Karma Candy KeHe Distributors Kellogg Company Kemin Industries Kentucky Eagle Kerry Inc. Kerry Ingredients & Flavours Keystone Foods Keystone Foods Keystone Foods Keystone Foods King Arthur Flour Co. King’s Hawaiian KLN Enterprises Klosterman/Hearth Grains Bakery Knott’s Foods Kraft Kraft Kraft Food Global, Inc. Kraft Foods Kraft Foods Kroger Kroger Kroger Kroger
64
Hamilton Allentown Battle Creek Des Moines Lexington Gridley Savannah Fairfield Fairfield Gadsden Fairfield Norwich Oakwood Perham Springboro Paris Chicago Columbus Champaign Federalsburg Frederick Cnty. Albany Cincinnati Indianapolis Murfreesboro
ON PA MI IA KY IL GA OH OH AL OH VT GA MN OH TN IL OH IL MD VA GA OH IN TN
Candy Distribution center Cereals pilot plant Animal food + D/W Beer distribution center Breakfast cereal Ingredients & flavors Cold storage Perishable/frozen foods storage Poultry Meat + D/W Flour D/W Bread Snack foods Bakery Sandwich spreads Cookies and crackers Perishable/frozen foods storage Food + D/W Bread products Beverages Peanut butter Ice cream Ice cream Dairy
June 2011 | Food Engineering | www.foodengineeringmag.com
Exp. 6 New 300 Exp. 157 Exp. New 188 Exp. 10 Exp. 120 Ren. Ren. 201 New 200 New 200 Exp. New 111 New 20 New Exp. Ren. Ren./New 931/20 Exp. Exp. 111 Exp. Exp. Exp. Exp. Ren./Exp. 20
14 29 3 11 Faithful+Gould Stellar Stellar 11 10 45 6 4 Hixson Stellar 8 2 40
11
The Dennis Group The Dennis Group The Dennis Group The Dennis Group
5/10 6/10 12/10 12/10 12/10 12/10 12/10 3/11 2/11 3/10 12/10 12/10 10/11 12/10 12/10 12/10 11 12/10 4/10 12/10 4/10 9/10 1/12 11/10 7/11
WE ’VE
BE EN
FA N AT I C A L –
TO
WHICH
ACCU S ED
OF
C R AF TS M ANS H I P WE
PL EA D
It shows up in the little things. The very little things. The things that would normally keep you up at night – but no longer will, because we’ve got them covered. Lock, stock and barrel. We admit it, we’re obsessive. We’re fanatics. And darn proud of it, because it makes for a project well done, and a client well pleased. Not to mention a ranking among the nation’s top 10 Food & Beverage contractors for the last 10 years. Call 800.748.4481 or visit www.big-d.com
G U I LT Y.
CONSTRUCTION SURVEY Company
City
Lafitte Frozen Foods Corporation Landshire, Inc. Leadbetter Foods Leprino Foods Lidestri Foods Lindt & Sprungli Litehouse Inc. Litehouse, Inc. Lofthouse Bakery Products Longitude 80 Dairies Louisiana Fish LVB Milling Lyons Magnus East
Lafitte St. Louis City Orillia Greely Greece Stratham Hurricane Lowell Ogden Statesville Baton Rouge Guelph Walton
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
L LA MO ON CO NY NH UT MI UT NC LA ON KY
Fresh/frozen seafood, D/W Packaged sandwiches Hamburger patties Cheese Food, pasta sauces Chocolate Prepared sauces Salad dressings, dips Bakery Yogurt Seafood canning Flour Pancake syrup/beverage bases
Exp. New Exp. New New New New Exp. New New New New Exp.
680 40 43 60 11
60
3 2 2 270 13 10 10 4 22 8 5 19 5
12/10 12/10 12/10 9/10 12/10 6/10 10/10 12/10 3/10 7/10 12/10 5/10 12/10
31 136 18 44 20 53 2 4 1 2 9
5/10 12/10 9/10 7/10 12/10 12/10 10/10 12/10 12/10 12/10 4/10 5/11 2/10 4/10 12/10 12/10 12/10 12/10 12/10 12/10 9/10 12/10 12/10 12/10 9/10 12/10 4/10 12/10 12/10 12/10
M Maidstone/Tim Hortons Inc. Malt-O-Meal Cereal Company Mane Inc. Maple Lodge Farms Mars Chocolate North America Mars Petcare Mars Snackfood Martek Biosciences Corp. Martin’s Potato Chips McCain Foods McCall Farms Inc. McCormick & Company, Inc. McLane Company Meadow Gold Dairy MediFast Inc. Mennel Milling Company Merchants Foodservice Miceli Dairy Michigan Milk Producers Association Mission Foods Mississippi River Distilling Co. Montana Eggs Moosehead Breweries Ltd. Mother’s Brewing Co. Mountaire Farms Mountaire Farms MP Foods Mr. Mudbug, Inc. Mt. Olive Pickle Company, Inc. Murphy Tomatoes
Hamilton Asheboro Lebanon Kentville Waco West Jefferson Waco Winchester Jackson Twp. Plover Effingham South Bend Republic Salt Lake City Coppell Roanoke Cnty. Tifton Cleveland Ovid Panorama City Le Claire Great Falls Saint John Springfield Lumber Bridge Millsboro Morton Slidell Mt. Olive San Antonio
ON NC OH NS TX OH TX KY PA WI SC IN MO UT TX VA GA OH MI CA IA MT NB MO NC DE MS LA NC TX
Coffee Cereal products + D/W Flavors Poultry Chocolate Pet foods D/W Confectionery Food additives Snack foods Potato products, frozen foods Canned foods Condiments, spices Grocery D/W Cooler Health supplements (meals) D/W Flour mill and distribution Food D/W Cheese Dairy Tortillas Distillery Eggs Beer Brewery Poultry Poultry Poultry Food custom packing Pickles D/W Tomatoes + D/W
New Exp. Exp. New Exp. Exp. Ren. Exp. Exp. Exp. New Exp. New Exp. New Exp. New Exp. New New New Exp. Exp. New Exp. New New New Exp. New
280
1300
55 450 5 55 8 107 60 200 6
40
138 32
The Dennis Group
Gray Construction 30 2
Big-D
4 8 5 62 50 1 3 35 2 18 34 8 5
N Nash Finch Company Nash Finch Company National Fruit Products Company Natura Pet Products Inc. Nestlé Nestlé Nestlé Nestlé Nestlé Nestlé Nestlé Nestlé Canada
66
Columbus Oklahoma City Winchester Fremont Bakersfield Chiapa De Corzo Danville Danville Queretaro Toluca Toluca Trenton
GA OK VA NE CA Mexico VA VA Mexico Mexico Mexico ON
Freezer, cooler, ambient storage Ambient storage Food processing Pet food Ice cream Coffee-mate creamer Pasta Pasta Food + R&D Coffee-mate soluble coffee Coffee Ice cream
June 2011 | Food Engineering | www.foodengineeringmag.com
Exp./Ren. Exp./Ren. Ren. Exp. Exp. Exp. Exp. Exp. New New Exp. Exp.
488 485 10
15 10 1 10
Food Tech LLC Food Tech LLC Epstein Middough
8 Middough Middough 26 390 100 16
10 10 07/10 8/10 10 12/10 10 10 3/10 12/10 3/10 5/10
Who says you can’t just glide through life? For quality and convenience, choose FiSan E-Z Glide, a revolutionary technology from Chemetall. Specially formulated for the Beverage Industry, FiSan E-Z Glide is a dry film lubricant that is approved for use on Glass, Polycarbonate, and PET bottles. With FiSan E-Z Glide, one lubricant is all you need.
800.526.4473 www.ChemetallAmericas.com
CONSTRUCTION SURVEY Company
City
Nestlé Dreyers Nestlé Prepared Foods and Baking Nestlé USA Nestlé USA Nestlé Waters North America Nestlé Waters North America Newly Weds Foods Newton Coffee Company Niagara Bottling Niagara Bottling Noni Biotech International LLC Northeast Foods Northeast Foods Northstar Agri Industries LLC
Ft. Wayne Solon Northbrook Taunton Pasadena Upper Macungie Horn Lake Marceline Lehigh Valley Phoenix Hilo Clayton Clayton Hallock
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
N IN OH IL MA TX PA MS MO PA AZ HI NC NC MN
Ice cream Frozen foods Pizzas Frozen entrée Water Bottled water Spices Coffee roaster + D/W Bottled water Bottled water Juice Bakery Bakery Canola
Exp. Exp. New Exp. New Exp. Exp. New Exp. New New New New New
Middough 4 19 The Dennis Group 312
12 103 80
5 1 2 1 35 1 13 25 100
AM King
10 8/10 12/10 4/10 12/10 12/10 12/10 12/10 12/10 12/10 12/10 5/11 7/10 12/10
O Ocean Spray Cranberries Ocean Spray Cranberries Ocean Spray Cranberries Ocean Spray Cranberries Omega Protein Inc. On-Cor Orlando Bakery
Markham Middleboro Tomah Wisconsin Rapids Abbeville Geneva Cleveland
WA MA WI WI LA IL OH
Fruit Fruit Fruit Fruit Meat Frozen foods + D/W Bakery
Exp. Ren./Exp. Ren./Exp. Ren. Exp. New Exp.
2.5 6.5 1 1
New Exp. New Exp. New Ren Exp. Exp. Exp. New Ren. Ren. Ren. New Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp. Exp.
16 100 170
Exp. Exp. New Exp. Exp. Exp. Exp. Exp.
135 23
55
4 4 2 2 2 14 1
The Dennis Group The Dennis Group The Dennis Group The Dennis Group
8/11 4/11 8/11 8/11 12/10 12/10 12/10
P Paina Hawaii LLC Palermo Villa Inc. Patterson Vegetable Co. Pepperidge Farm PepsiCo Phoenix Packaging Group Pierre Foods Pierre Foods Pierre Foods/Cloverdale Pierre’s Ice Cream Co. Pilgrim’s Pride Pilgrim’s Pride Pilgrim’s Pride Pilgrim’s Pride Pinnacle Foods Pinnacle Foods Pinnacle Foods Pinnacle Foods/Armour Star Planters Company Inc. Pontiac Coffee Poppee Popcorn Port City Bakery Prairie Farms Dairy, Inc.
Kunia Milwaukee Patterson East Brunswick Seattle Pulaski Claremont West Chester Twp. Amherst Cleveland Douglas Dallas Nacogdoches Natchitoches Cherry Hill Jackson Jackson Fort Madison Fort Smith Elgin North Ridgeville Green Bay Granite City
HI WI CA NJ WA VA NC OH OH OH GA TX TX LA NJ TN TN IA AR SC OH WI IL
Fruit Pizza Frozen vegetables Bread Soft drinks + D/W Private-label food Meats/frozen sandwiches Meat Prepared foods Ice cream Poultry Chicken Chicken Poultry Frozen/shelf-stable foods Frozen foods Bakery Canned meats Roasted nuts Roasted coffee Popcorn Bakery Milk products + D/W
450 110 45
2 22 The Dennis Group The Dennis Group
17 27 3
35 130
57 12 17 2.7 15 18
Stellar VCP&A VCP&A 10 6 12 Stellar 20 20 7 1 10 12
The Dennis Group
12/10 8/10 4/12 5/10 12/10 10/10 7/10 12/10 12/10 10/10 2/11 10/10 5/11 12/10 10/10 12/10 5/11 12/10 12/10 3/12 12/10 12/10 4/10
R Rare Breed Distilling LLC Red Gold Redbarn Pet Products Request Foods Inc. Reser’s Fine Foods Rich Products Rolfs Patisserie RTD Beverages, LLC
68
Lawrenceburg Orestes Great Bend Holland Halifax Waycross Pleasant Prairie Goodbee
KY IN KS MI NC GA WI LA
Distilled spirits Tomato products Pet food Frozen food Prepared foods Dough enrobed products Commercial bakeries Tea/bottled water
June 2011 | Food Engineering | www.foodengineeringmag.com
200 23 56
50 20 2 35 15 9 4 4
12/10 12/10 12/10 2/10 12/10 12/10 12/10 12/10
HEAT IT. COOL IT. POUR IT. PACKAGE IT. SHIP IT. JUST BE SURE TO HAVE A STONHARD FLOOR UNDER IT. At Stonhard we do more than create long lasting, great looking floors. Our more than 350 project engineers and 200 specially trained installation crews provide the food and beverage industry with precise solutions. From custom designs and project support to proven performance and comprehensive service, we solve your toughest flooring problems. Our extensive line of seamless floor systems dramatically impacts your bottom line by eliminating repairs and year after year investments in new floors. Our chemical, impact and abrasion resistant floors are also sanitary, safe and easy to clean. And all from a company that doesn’t believe in a one-size fits all approach to seamless flooring. That’s why 95% of our business comes from repeat customers. Unparalleled products, seamless, custom designs and our reliable single source warranty. It’s always a great time to talk to us.
Industrial
Institutional
Commercial
Stonhard is an ISO 9001 Registered Company ©2011 Stonhard®
800.257.7953
stonhard.com
FLOORS FOR EVERY ENVIRONMENT
CONSTRUCTION SURVEY Company
City
Ruprecht Co.
Mundelein
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
R IL
Meat D/W
Exp.
107
New Ren. Ren. Exp. New Ren./Exp. Ren. Ren. Exp./Ren. Exp. Exp. New Exp. New Exp. Exp. New Exp. New Ren./Exp. Exp. Exp.
110 15
5
6/10
S Sabra Dipping Co. Sabra Dipping Co. Sabra Dipping Co. Sandridge Corp. Saputo Dairy Products Canada Sara Lee Foods Sara Lee Foods Sara Lee Foods Sara Lee Foods Schreiber Foods, Inc. Schreiber Foods, Inc. Schuler’s Bakery Schwan Food Company Seccas Sensient Colors Sensus LLC Shamrock Foods Shearer’s Foods Shearer’s Foods Sheetz Bros. Shirley’s Cookie Company Short’s Brewing
Colonial Heights Colonial Heights Colonial Heights Medina Vaughan Forest Park Haltom City Kansas City San Lorenzo Shippensburg Stephenville Springfield Stilwell Pittston St. Louis City Hamilton Natomas Massillon Massillon Claysburg Claysburg Elk Rapids
VA VA VA OH ON GA TX KS CA PA TX OH OK PA MO OH CA OH OH PA PA MI
Hummus Hummus Hummus Fresh refrigerated foods (HPP) Dairy products + D/W Food Meat products Multiple Meat Dairy Cheese Baked goods Frozen desserts/vegetables Bottled water Natural colors Flavors Dairy DC Snack foods Snacks Frozen foods Cookies Beer
The Dennis Group The Dennis Group The Dennis Group
7 237 11 15
16 130
150 52 64 12
2 1 8 2 1 3 16 2
Hixson Stellar Hixson Hixson
27 5 1 1
The Dennis Group
From R&D through full-scale production
Creating state-of-the-art food and beverage facilities for every stage in the product lifecycle since 1948 www.hixson-inc.com
70
June 2011 | Food Engineering | www.foodengineeringmag.com
5/11 2/12 10/11 4/10 5/10 10 3/11 10 2/10 12/10 12/10 12/10 12/10 12/10 4/10 12/10 11/10 7/10 4/10 6/12 12/10 12/10
Company
City
Sister Schubert’s Homemade Rolls SK Food Group Slimfast Nutritional Products Smith Dairy Smith Provision Company, Inc. Smithfield Foods Inc. Solbar Industries Sopakco South Atlantic Canners Southeastern Mills Southern Press & Packing Corporation Spangler Candy Co. St. Albans Cooperative Creamery Inc. StarKist Company Sterling Sugars, Inc. Steuben Foods Inc. Stolthaven New Orleans, LLC Stonyfield Farm Studers Dairy Sugar Creek Packing Co. Sugar Creek Packing Co. Sunnico Meats Sunny Delight Sunny Delight Beverages Company Sunshine’s Pride Dairy LLC Swan Valley Cheese
Horse Cave Reno Covington Orrville Erie Isle of Wight Cnty. South Sioux City Marion Bishopville Rome Blackshear Bryan Saint Albans Pittsburgh Franklin Elma Braithwaite Londonderry London Dayton West Chester Twp. Les Cedres Dayton Blue Ash Winchester Swanton
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
S KY NV TN OH PA VA NE SC SC GA GA OH VT PA LA NY LA NH ON OH OH QC NJ OH VA VT
Baked goods Sandwiches Dietetic drinks Dairy, ice cream Meat Meat Soy protein isolates Microwave meals Soft drinks + D/W Ingredients Blueberries/juice drinks Candy Dairy Foods, tuna, etc. Sugar cane mill Milk/bottling Soybeans Yogurt Dairy Bacon Bacon Meat packing Juice Beverages Cheese/meat products Cheese
Exp. Exp. Exp. New New Exp. Ren. New Exp. Ren. New Exp. Exp. Exp. Exp. Exp. Exp. Ren. New Exp. Exp. New Exp. Exp. New New
50 65 32 50 139 195 200
Gray Construction 7 100 20 7 20 16 4
30 9 25 32 90
The Austin Company 2 5 2 1 2 52 27 The Dennis Group
10
1 3 1
134 The Dennis Group 100
70 10 6
7/11 12/10 3/10 12/10 12/10 7/10 10/10 12/10 9/10 03/11 12/10 12/10 12/10 12/10 12/10 8/10 12/10 8/10 5/10 12/10 12/10 5/10 6/10 12/10 7/10 12/10
* TankJet® 360 Tank Cleaner
Downtime for tank cleaning can significantly impact production levels. Our recently expanded tank cleaning product line includes many solutions to clean your tanks in less time – and return them to service more quickly without compromising cleaning quality. Whether your tanks are 2 ft. or 100 ft. (0.6 or 30 m) in dia.; require rinsing or high-impact cleaning, our local sales engineers will help you select the right tank cleaner. The results: UÊVÀi>Ãi`Ê«À`ÕVÌÊÌi UÊ«ÀÛi`ÊVi>}ÊVÃÃÌiVÞÊ
i>ÀÊÀiÊ>ÌÊÌ>iÌ°V
TankJet 65 Tank Cleaner
See Food Master, p. 110-111
TankJet AA190D Tank Cleaner
TankJet 18250A Tank Cleaning Nozzle
* Reductions in cleaning time will vary based on current cleaning methods and the tank cleaner installed. Multi-hour operations can often be reduced to 60 minutes or less.
www.foodengineeringmag.com | Food Engineering | June 2011
71
Corporate Profile the globe. From our headquarters in Jacksonville, corporate offices in Atlanta, Dallas, and Mexico City, and project offices worldwide, Haskell serves our customers in North America, Latin America, Europe and Asia. Expanded Portfolio Haskell has expanded its product offerings to include both process and packaging system integration. Through organic growth and acquisition, Haskell now has a full complement of system integration engineers with years of experience in virtually every segment in the food and beverage industry. Whether you are looking for a pre-
H
askell is an acknowledged industry leader in
liminary engineering study to evaluate a plant or system
the design and construction of world class
expansion, or a partner to design and build a greenfield
manufacturing facilities for the food and bever-
facility and the systems within it, the Haskell team has the
age industry. As the nation’s leader in sustainable
resources and expertise to meet your needs.
design and construction, Haskell builds energy efficient facilities for Top 50 companies in the
Experienced Resources
industry and has long been known for its innova-
Our team of over 700 engineers and construction man-
tion in design and efficiency in project execution.
agers are experts in project delivery for the food and beverage industry, consumer products industry and
Global Reach
other manufacturing industries. This diverse expertise
Haskell supports our multi-national customers
adds value to our customers as we bring technologies
with engineering and construction services across
and approaches from a wide range of applications to
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tions to meet their business needs.
Our promise to our customers is certainty of outcome. Through our EPC delivery methods we
Flexible Contracting
are prepared to take on every aspect of project
At Haskell we focus on the business needs
delivery and provide an end-to-end solution.
of our customers and are flexible in our
We have the integrated team of professionals
approach to contracting. We are prepared
required to make that commitment to you and
to deliver complete solutions for facilities
are prepared to back up that claim by taking
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a successful outcome. With Haskell you can be
will also support the customer with subsets
assured we will deliver “The four walls and every-
of that approach as needed.
thing within”.
Contact Information Haskell - Corporate Headquarters John-Paul Saenz, VP Food & Beverage Division 111 Riverside Ave., Jacksonville, FL 32202 Phone: (904) 791-4500 A Haskell Company
Haskell America’s Design-Build Leader®
FAX: (904) 791-4699
www.haskell.com
CONSTRUCTION SURVEY Company
City
Swartz Soybean Swire Coca-Cola Synergy Flavors, Inc. Sysco Foods Sysco Foods Sysco Foods Sysco Foods Sysco Foods
Montezuma Draper Wauconda Houston Lincoln Plant City San Antonio West Jordan
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
S GA UT IL TX NE FL TX UT
Soybean crushing facility Distribution center Flavoring syrups Distribution center Cooler/freezer Perishable/frozen foods storage Distribution center Cooler/freezer/cold dock
Exp. Exp./Ren. Exp. New Exp./Ren. Ren. New Exp./Ren.
10 370
2 Big-D 10
635 200 40 640 46
Big-D Big-D Stellar Big-D Big-D
12/10 1/12 12/10 3/10 3/12 11/11 11/10 4/10
T Tate & Lyle Taylor Farms Taylor Farms TDL Group Testa Produce Texas Star Nut and Food Co. The Boston Beer Company The Boston Beer Company The Boston Beer Company The Boston Beer Company Three Dog Bakery Tip Top Poultry Tony’s Fine Foods Toufayan Bakeries Tribe Mediterranean Foods
Hoffman Estates Salinas Salinas Kingston Chicago Boerne Allentown Allentown Allentown Cincinnatti Kansas City Rockmart West Sacramento Plant City Taunton
IL CA CA ON IL TX PA PA PA OH MO GA CA FL MA
Ingredients Packaged salads Packaged salads Distribution center Food DC Nuts Beverages Beer Beer Beer Dog and cat food Poultry Perishable foods Bread Mediterranean foods
New Ren. New Exp. New Exp. Exp. Ren. Ren. Exp. Exp. Exp. Exp. Exp. Exp.
100 50 110 20 90 15 10 n/a n/a
12 35 83
26 The Dennis Group The Dennis Group 33 2
Epstein The Dennis Group The Dennis Group The Dennis Group The Dennis Group
2 5 4.6
Food Tech LLC
12/10 4/11 12/10 9/10 3/11 12/10 4/11 9/11 2/11 5/10 12/10 12/10 5/11 3/10 7/10
DESIGN-BUILD SERVICES for food and beverage facilities
The Austin Company is a leader in providing design-build services for clients nationwide. Austin ensures a seamless project execution, while saving time and money in delivering high-quality projects. Representative clients include: Colgate-Palmolive, Coca Cola, Bimbo Bakeries USA, Martek Biosciences, Russell Stover Candies, The McIllhenny Company and Danisco.
INTEGRATED PROJECT DELIVERY
Please contact us at
[email protected] or www.theaustin.com/foodgroup
CONSULTANTS
DESIGNERS
ENGINEERS
A company built on delivering “Results, Not ExcusesTM”
74
June 2011 | Food Engineering | www.foodengineeringmag.com
CONSTRUCTORS
Company
City
State
Trim-rite Food Corporation Troegs Brewing Company True Cajun Seasoning Company, LLC Truitt Bros Inc Twin Marquis Foods Tyson Food Services Tyson Foods Tyson Foods Tyson Foods Tyson Foods Tyson Foods Tyson Foods Tyson Foods Tyson Foods
Rantoul Hershey Lake Charles East Bernstadt Brooklyn Monroe Broken Bow Center Noel Shelbyville Wilkesboro Houston New Holland Robards
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
T IL PA LA KY NY NC OK TX MO TN NC TX PA KY
Hog slaughter + D/W Brewery Spices and extracts Shelf-stable meals Asian food Poultry Poultry Chicken Chicken Poultry Chicken Meat Poultry Chicken
New New New Exp. Exp. Exp. Exp. Ren. Ren. Exp. Ren. New Exp. Exp.
128 90
6 1 9 1 2 9
18
VCP&A VCP&A 5
22 100 90
VCP&A 10 1 6
12/10 12/10 12/10 12/10 12/10 9/10 12/10 8/10 2/10 5/10 4/10 12/10 12/10 12/10
U U.S. FoodService Unilever United Natural Foods United Pet Group United Supermarkets
Port Orange Covington York Montgomery Cnty. Lubbock
FL TN PA VA TX
Distribution center Ice cream, frozen treats + D/W Warehouse/DC Pet food Ready-to-eat food
Exp. Exp. New Exp. Exp.
32 675
33 100
7/11 1/10 9/10 7/10 12/10
3 4
v Valley Fine Foods
Benicia
CA
Cooler/freezer/process
Ren.
20
3
E.A. Bonelli & Assocs.
1/10
Over 25 years in the Food and Beverage Industry! KAGETEC provides chemical resistant, K\JLHQLF LQGXVWULDO ÀRRULQJ V\VWHPV consisting of slip-resistant ceramic tile and integrated stainless steel drains. Gleeson Constructors & Engineers, L.L.C. specializes in the design and construction of food processing facilities, cold storage facilities and distribution centers nationwide.
Engineers Designers Builders
2015 E. 7th Street Sioux City, IA 51101 Ph: (712) 258-9300 fax: (712) 277-5300 www.gleesonllc.com
KAGETEC USA | p.612.435.7640 www.kagetecusa.com |
[email protected]
www.foodengineeringmag.com | Food Engineering | June 2011
75
CONSTRUCTION SURVEY Company
City
Ventura Foods, LLC Vermont Butter & Cheese Company VersaCold Viandomax
Opelousas Websterville Port of Tacoma Chicoutimi
State
Primary Product
Type
Sq. ft. Cost (000) ($ Mil.)
A/E
Comp. Date
V LA VT WA QC
Fats and oils Soft cheese Refrigerated DC Meat
Exp. Ren. New New
7 196
2 1.4
12/10 06/12 7/10 5/10
Food Tech LLC
2
W Wacker Wellington Foods Inc. White Castle Systems Inc. WhiteWave Foods Wholesome Pet Wildgame Innovations Williams Selyem Wrigley
Eddyville Corona Evendale Dallas Smithville New Roads Healdsburg Chattanooga
IA CA OH TX OH LA CA TN
Food ezymes Nutritional supplements Bakery Multiple foods Pet foods D/W Deer feed and supplements Wineries Confection
Exp. New Exp. Exp. New Exp. New Exp.
Middough 116 16
10 10/10 12/10 11 12/10 12/10 12/10 10
20 Hixson
30
1 3
28 Middough
Y Yakult USA Yukiguni Maitake
Fountain Valley Manakating
CA NY
Milk Nutraceutical mushrooms
New New
387 496
New New Exp. Exp.
130 14 73
6/10 12/10
Z Zatarain’s Brands, Inc. Zitner Candy Corporation Zoomessence Inc. Zwanenberg Food Group
Gretna Philadelphia Hebron Green Twp.
LA PA KY OH
Spices and extracts Candy Flavors and ingredients Meat processing
5 1 1 12
12/10 12/10 12/10 12/10
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June 2011 | Food Engineering | www.foodengineeringmag.com
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© 2011 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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FOOD AUTOMATION & MANUFACTURING CONFERENCE ` Networking is the name of the game, and when it can be done while socializing, all the better.
Manufacturing best practices shared Need-to-know manufacturing concepts and professional contacts kept food professionals engaged during the annual Food Engineering conference. ` Kevin T. Higgins, Senior Editor
M
anufacturing professionals are loath to leave their centers of operation. To lure them away for a few days, there has to be a better payoff than sunny skies and elegant surroundings. Based on attendee feedback, there was plenty of steak to accompany the sizzle at Food Engineering’s 2011 Food Automation & Manufacturing Conference and Expo, an annual event that drew 250 to the Ritz-Carlton in Palm Beach, FL for three and a half days in early April, including 174 registrants to the conference portion of the program. More than 18 hours of presentations by experts in OEE monetiza-
tion, plant safety, innovation management, energy management and a variety of other topics provided a briefcase full of takeaways for attendees to consider at their own facilities. Fundamental change is occurring in how food is processed and raw materials are handled and accounted for as food safety requirements become more stringent, suggested Greg Flickinger, manufacturing director for Charlotte, NC-based Snyder’sLance Inc. The snack food manufacturer recognized this in the wake of the 2009 Peanut Corporation of America Salmonella contaminations: Although the company was not involved in the recall, the headquarters plant was besieged by state and federal
www.foodengineeringmag.com | Food Engineering | June 2011
79
FOOD AUTOMATION & MANUFACTURING CONFERENCE
` The pool area at the Ritz-Carlton sets an elegant tone for the welcome reception at this year’s Food Automation & Manufacturing Conference.
inspectors, with more than 100 swab tests conducted to determine if contact surfaces were microbiologically clean. To succeed in this new environment, management concluded a high-performance work system had to replace traditional approaches, with quality checks pushed down to the operator level. “Quality and food safety is owned by operators,” said Flickinger. “QA no longer is the police force; it now is the support group.” Adding structure and documentation to the new order is a protocol the firm calls CILT: clean, inspect, lubricate, tighten. Downtime as well as uptime tasks are detailed, helping to train workers in standardized procedures and build consistency. “Once you have a structured program, you can dive deeper,” he said, though CILT is not a panacea. “The tool doesn’t fix your problem; people do,” Flickinger emphasized. Performance improvement is reflected in a 17 percent reduction in cost per pound of finished goods, a 52 percent cut in consumer com-
plaints and 16 successful third-party audits, including SQF Level 3 safety audits at three plants. Ownership is challenging engineers and other manufacturing professionals to deliver those types of results without any capital outlays. Getting more out of the equipment on hand is the point of the overall equipment efficiency (OEE) metric. Peter Hock, senior director of continuous improvement at Omaha, NE-based ConAgra Foods, provided a detailed discussion of using OEE to focus on the fundamental drivers of yield loss. “All parts of OEE are not created equal,” he said. “Each OEE bucket has its own profile and penalties.” Hock recommended monetizing OEE losses, developing a “cost opportunity Pareto” and then involving financial managers to focus resources on projects with the greatest impact. Total productive management drives root cause analysis of where the best improvements reside at ConAgra, though the continuous-improvement methodology is less important than the execution. The company is striving for 85 percent OEE, though that may be mathematically impossible: Sanitation cycles of 3½ hours on frozen food lines, for example, lop 10 points off OEE calculations at the outset. Regardless of the goal, a cross-functional team is essential. “The change-management issue cannot be underplayed,” Hock concluded. “People have to see the benefit change will make. Where we’ve taken a command and control approach, we’ve generally fallen down.” Reliable data provide a starting point for cost reductions and other initiatives in manufacturing,
CPG meets HBS Gaining approval for projects is one of engineers’ greatest challenges, and training in modern financial metrics at Harvard Business School might do more for the career of tomorrow’s food engineers and other consumer packaged goods production experts than coursework at Georgia Tech, based on a presentation by Dan Fonner, senior manager-global utilities at Heinz North America. Fonner discussed a number of innovative projects that he has helped guide as part of Heinz’s objectives to reduce energy and water consumption 20 percent and increase renewable energy use 15 percent. “Back in 2005, it was [called] utility optimization; today, it’s sustainability,” he noted, “but it’s the same mix” of efficiency-driven initiatives. Significant progress toward those goals has been achieved over five years, with electrical reductions of 36 million kWh and 4.9 billion gallons of water saved as a result of 101
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projects, including T-5 fluorescent upgrades at all 20 Heinzowned North American plants. More ambitious initiatives can be derailed, however, after years of discussion and the enthusiastic support of top management. A prime example is a 2009 water recycle and biogas-generation project at Heinz’s French fry facility in Ontario, OR. The plant has been heavily fined and mandated to clean up discharges into the Snake River. The project would have recycled 90 percent of water and saved 1 billion gallons annually, plus reclaim enough heat energy to warm 3,400 Oregon homes. “After a year and a half, [it was a] no go,” Fonner explained, because, despite positive cash flow of up to $1 million, no money down and no balance sheet impact, financial experts determined too much cash would be tied up. Despite the discharge issues, the Ontario plant received the Energy Star designation last year.
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FOOD AUTOMATION & MANUFACTURING CONFERENCE ` In conjunction with the conference, Expo 2011 provided an opportunity to learn more about innovative products and services.
To illustrate, Wolf cited recent efforts to establish a single management system for safety and environmental (S&E). A goal of zero accidents is the easy part: Developing consistent definitions, policies, procedures and expectations requires engagement of employees and strategic partners. The acquisition of 67 Cadbury plants last year added two S&E systems to the three Kraft already had, resulting in enormous redundancy and inconsistency. A global team resolved the issue. “Everyone had to change a little, but in the end, we had a system everyone could accept,” she said. As a result, accident-reduction goals have been recalibrated to 50 percent, almost triple the improvement previously sought. which is why Kraft Foods Inc. standardized on SAP in European and North American plants and expects to have the rest of its global production network using SAP by 2013, according to Diane Wolf, global vice president-safety, environmental & sustainability at the Northfield, IL firm. Consistent KPI metrics ensure a “common look and feel” to every plant’s measurement of the pillars of manufacturing excellence—quality, cost, delivery, safety, sustainability and morale. But consistent metrics require consensus, and that becomes a challenge as business units are bought and sold.
Food safety and worker safety A dozen subject-matter experts from the supplier community added their perspectives to some of the issues raised in the 17 presentations by food company professionals. Food and worker safety are never far from anyone’s thoughts, and two suppliers tackled those topics head on. Citing a doubling of food and beverage recalls to 565 in 2008 from the 255 in 2005 and 240 in 2006, Siemens Industry Inc.’s Walt Staehle suggested “risk communication and control are the key elements of brand protection, not technology.” None-
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Anatomy of a Plant of the Year Calculated risk taking, best-of-breed concepts and a commitment to building the world’s most sustainable snack food manufacturing site helped shape the design and execution of Shearer’s Foods Inc.’s plant in Massillon, OH, winner of this year’s Food Engineering Plant of the Year Award and the first LEED platinum food manufacturing project, according to Scott Weyandt, sustainability director at Brewster, OH-based Shearer’s. Before accepting the award at the Food Automation & Manufacturing Conference, Weyandt highlighted some of the innovations and advanced automation systems in Massillon. Among them is a low-water corn cook process that reuses stored thermal energy and taps oven-exhaust energy to preheat cook water, helping to reduce process energy demand 15.9 percent. Even greater energy savings are realized from a first-of-its kind tortilla oven with a sealed cavity and 24 banks of concave infrared burners that produce both convective and radiative heat. When Shearer’s solicited proposals from vendors, “some presented same-old, same-old designs with ribbon burners,” Weyandt said.
theless, technology can help reduce the time required for root cause analysis of a recall event, a key factor in containing the financial and public goodwill damage that results.
The advanced technology will reduce per unit energy requirements 47 percent. Linear layouts with long, unobstructed views from receiving to shipping were the norm in plant design until recent years. The Massillon plant reflects a new approach featuring zoned areas for various parts of the process. “Everything is feeding to the center and exiting out one of the sides,” explained Weyandt. Besides providing greater hygienic control, the design more easily accommodates expansion, an important advantage in Massillon, where an addition this year more than doubled plant size to 110,000 sq. ft. State-of-the-art automation and controls were incorporated for both operations and building systems. The proprietary Manufacturing Information Portal interfaces with ERP scheduling and provides OEE, downtime information, and capacity and production comparisons, while Infinity QS software ensures quality checks are made as scheduled and SPC information is presented to operators in an actionable way, Weyandt said. Despite the advanced systems, he pegged ROI at 2.98 years, “and some of the greatest savings didn’t cost a dime” extra.
Public support for food safety regulations hovers around 89 percent, the manager of Siemens’ food & beverage services said, though the implementation outlook for the Food Safety Mod-
ceeding expectations in the food industry.
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FOOD AUTOMATION & MANUFACTURING CONFERENCE ernization Act is unclear. Although the legislation passed with industry support, political maneuvering has put implementation funding in doubt, according to David Dixon, senior director-strategic accounts for the Kansas City-based engineering firm Burns & McDonald. But business partners are demanding improvements in safety systems and san-
itary designs, prompting many plants to invest in better HVAC systems and more robust cleaning protocols. Dixon notes a trend toward more wet washdown and high-ticket improvements to ceilings, walls, floors and blockage of penetration points to processing areas. New dust collectors and other systems to minimize explosion threats from
See Food Master, p. 53
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combustible dust is another big area of spending, he said, notably in Georgia, where tough new regulations were enacted in the wake of 2008’s explosion at Imperial Sugar’s Port Wentworth, GA. Most organic materials will explode if divided into particles less than 420 microns in diameter, pointed out Kevin Jeffries, who joined Imperial Sugar as corporate safety systems manager in the wake of the explosion that claimed 14 lives. While OSHA is still developing explosion-prevention standards, the state of Georgia adopted as law the standards promulgated by the National Fire Protection Association, according to Jeffries. Total elapsed time in Imperial’s twostage explosion was 325 milliseconds, with most of the destructive power unleashed in the secondary explosion. The plant, which was built in 1917, had operated without incident for 91 years until the tragedy. Explosion prevention is a continuous improvement challenge, Jeffries emphasized, and any plant where dust can be suspended in a confined space is vulnerable. He elaborated on six essentials of prevention: • Identify the hazard • Define scope of hazard in the process • Identify controls to address hazards • Find and screen resources • Document everything • Sustain performance. Sustainable manufacturing practices and corporate social responsibility were
` Heinz North America’s Dan Fonner was one of 17 food company professionals, along with subject-matter experts, to speak at the 2011 conference.
the focus of the final day’s presentations. The 146 food plants operated by members of the Northwest Food Processors Association are committed to lowering their energy intensity 25 percent in 10 years and 50 percent in 20, explained Peter Truitt, vice president and cofounder of Truitt Brothers, a Salem, OR cannery with a second plant in Kentucky. Production volume is the equation’s denominator, and energy consumption is standardized by BTUs—91,600 BTUs for a gallon of propane, 3,412 BTUs for 1 kWh, etc. More efficient equipment and better operations and maintenance practices are expected to produce almost half the reductions in energy intensity, with distributed generation process improvement and energy management accomplishing the rest. “As a shelf-stable company, retorts are us, and we’re ignoring the elephant in the room if we don’t” upgrade boilers and install better controls technology at some point, Truitt allowed. For the time being, the focus is on low-/no-cost projects and equipment upgrades that qualify for funding assistance. Eight hydraulic pumps were replaced for $32,084, saving 126,069 kWh/year, or $8,169, but ROI would have stretched almost four years if incentives weren’t available. “If it weren’t for the tax credits, a lot of these projects wouldn’t be possible,” he observed. Nonetheless, sustainability outreach often results in less expensive processes and “are just good common sense,” he said. They also tend to unleash creative ideas. “Once people understand where you’re headed, they grab hold of things and run with them,” Truitt concluded. “I’m no longer the cop; we’ve got a bunch of deputies who are engaged and accountable to each other.” Both Keystone Foods and Smithfield Foods Inc. are major suppliers to McDonald’s Corp., and both have been honored by the restaurant chain for their sustainability programs, a priority for all McDonald’s supply-chain partners. Social responsibility is a natural extension of those efforts, according to Keystone’s Ed Delate, vice president-global engineering and corporate social responsibility. Energy-reduction efforts alone have saved
the company more than $10 million annually, and engaging both workers and suppliers is producing best practices that otherwise never would be considered. Dennis Treacy, who became Smithfield’s first chief sustainability officer last year, suggested demonstrating social responsibility was important in being an employer of choice, engaging company
critics and effecting improvements in both food and worker safety. Maintaining business-to-business relationships is also a prime motivation, he concedes. “The supply chain is becoming the government,” Treacy observes. “If Walmart or McDonald’s or someone else who buys our products insists on something, we’re going to do it.” ❖
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How safe is the food we eat?
We use innovative technologies to safeguard the food supply chain – from the manufacturer to the supermarket. 6LHPHQVVXSSRUWVIRRGDQGEHYHUDJHPDQXIDFWXUHUVDOORYHUWKHZRUOGLQPHHWLQJIRRGVDIHW\VWDQGDUGV:HRIIHU V\VWHPVWKDWPRQLWRUWKHPDQXIDFWXULQJSURFHVVDQGSURYLGHLQWHOOLJHQW5),'VROXWLRQVZKLFKGRFXPHQWWKHHQWLUH URXWHWDNHQE\IRRGV:LWKRQHJRDO WRPDNHVXUHWKDW\RXFDQFRQWLQXHWRHQMR\\RXUIRRGZLWKQRQDJJLQJGRXEWV ZZZXVDVLHPHQVFRPIRRGEHY
Answers for industry.
TRACK & TRACE ` Kroger provides freshness and sourcing data to consumers, in store, using their Smartphones. Source: HarvestMark.
Multifunctionality delivered Today’s track & trace systems do much more than help you meet regulations. They can improve products, operations and relationships with customers and consumers. ` Olin Thompson, Contributing Editor
A
s food safety regulations have been modified, so too have consumer expectations related to safe and healthy eating. While track & trace systems are not new, processors are showing these can do more than satisfy regulators; they can improve products, operations and processors’ relationships with customers and consumers. Consumers are paying closer attention to food and changing how they shop. According to Chris Peterson, director of the Product Center at Michigan State University, “Nearly half of the consumers we surveyed expressed a change in shopping patterns because of food safety.” The good news is that while most consumers report low prices as the main reason why they purchase a product, 60 percent of respondents say they are willing to pay up to 10 percent
more for food that promises to be healthier, safer or produced to higher ethical standards. The Food Safety Modernization Act, signed into law on January 4, 2011, contains many new and altered regulations and specifically covers enhanced track & trace and recordkeeping requirements. A major impact to processors is the provision that requires all members in the food supply chain to maintain “one step forward, one step back” traceability information in digital form. The requirement for a “digital form” means paper and pencil efforts will no longer meet the regulations, and some level of computerization is now mandated. While some of the regulations are already in place, the new law will result in other changes over the next two years. The legislation requires FDA to conduct product tracing pilots within nine months of enact-
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TRACK & TRACE building compliance and traceability into production systems remains the most frequent strategy, with 62 percent of food companies employing this option. The study also shows 75 percent of food companies utilize ERP systems to capture trace & track information. Most food and beverage manufacturers have adopted ERP as the major system of record and for managing end-to-end business processes. ERP collects, organizes, analyzes and presents the vast majority of the operational information available to 2010 food processors. From supplier receipts to produc2009 tion to inventory to customer shipments, data is collected as part of ERP’s role in company manage50 60 70 ment and accounting. When properly implemented, ERP builds in traceability information with no incremental cost of collecting this data. However, out of the many ERP products available, only a few are focused on food processing, offering track & trace functions; most include mature functionality that has been proven in numerous food implementations. The collection of track & trace information is built in, but little difference exists across the various vendors. The vendors compete on how data is made available in case of an incident.
Food Industry Market Pressures Adhere to government regulatory requirements
Ensure product quality and consumer satisfaction
Reduce the number of non-compliance and recall events
Maintain or achieve a competitive advantage
Reduce the cost of manufacturing operations
Source: Aberdeen Group, 2010.
0
10 20
30 40
ment. Within 18 months, FDA must provide Congress with a report on recommendations for establishing more effective product tracing, including consideration of costs and benefits, feasibility of technologies for different sectors, existing practices and international efforts. Using the information, FDA is directed to create, as appropriate, a product tracing system. Within two years, FDA must begin developing regulations for additional recordkeeping requirements for high-risk food. According to Mike Hader, director of information technologies at Odom’s Tennessee Pride Sausage, “The ever-changing status of food safety regulation requires companies to comply with strict standards and controls, and the marketplace rewards those who can embrace a culture of driving quality throughout the entire supply chain.” For a system to be great, Hader states, “It not only needs to do everything you need, it also must be rock-solid reliable and extendable. We can be assured that we can always trace the pedigree of everything that goes into our products and where our products were sold. While there is no ROI that can be measured for this ability, it is priceless if and when you need it.” The processor of breakfast foods uses Infor Global’s Adage ERP system. Changed motivation Late in 2010, The Aberdeen Group, a research organization based in Boston, MA, produced a study titled Food Safety and Traceability: Ensuring Compliance and Enabling Supply Chain Visibility. Aberdeen has produced studies on this topic for the past five years. Reviewing past reports, it’s clear the industry’s motivation for improving food safety and traceability has changed. In 2009, the top motivator focused on the reduction of in-compliance events and recalls, a proactive effort to minimize the impact of quality issues. However, the 2010 study shows the industry has become less focused on prevention and more focused on meeting government requirements, a reactive effort. The study also shows an increased interest in using food safety and track & trace for competitive advantage and cost reduction. Although the Aberdeen study shows a major change in market pressures, the strategic actions being deployed have not changed; 88
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Standards evolve As the industry focuses on the extended supply chain, there has been a growth in standards. For example, GS1 US, along with other industry associations such as United Fresh, has focused on best practices and standards for traceability and the extended supply chain. These organizations have developed initiatives, like the Produce Traceability Initiative (PTI), to help companies better manage the flow of data within and between organizations. The initiatives also promote the adoption of Global Trade Item Number (GTIN) and Global Location Number (GLN), with the ultimate goal of achieving whole-chain case-level electronic traceability by 2012. In addition, PTI is being used as a template for adoption across a number of categories outside of produce, including seafood, meat, dairy, baked goods and more. According to Matthew Littlefield, senior research analyst, manufacturing, at Aberdeen, “The best-in-class companies are again leading the charge in the adoption of these standards, with the best-in-class being over three times more likely than laggards to be leveraging these standards in their business processes. “GS1standards are making major strides,” Littlefield adds, “specifically in the food and beverage industry, for sharing information between partners.” Other technologies also play a role. In response to the increased focus on food safety and traceability, a wave of software, hardware, consulting and systems vendors have emerged over the last few years to offer a range of traceability solutions and tools. Radio frequency identification (RFID) and barcodes are two common technology methods used to deliver traceability.
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TRACK & TRACE ent suppliers, capturing information from their certificates of analysis (CoAs). When this pro“Build in” compliance and traceability to production processes cessor started comparing CoA information Improve visibility and control of quality across the enterprise to its specifications, a significant number were f lagged as red Increase responsiveness to non-conformances (out of spec) or yellow (trending towards Improve the quality performance of critical suppliers out of spec). The vice president talks about Create closed-loop feedback from customer complaint to manufacturing operation the practical realit y of validating inbound Source: Aberdeen Group, 2010. 0 10 20 30 40 50 60 70 ingredients: “Before this system, we were only checking a small percentage of CoAs against our specs, Barcoding is a common and cost-effective method used to critical ingredients and suppliers with known quality issues. implement traceability at both the item- and case-level. Variable Therefore, we simply did not know if ingredients were meetdata in a barcode can include the lot number and can be applied ing our specs. Now, everything is checked 24/7.” Since a CoA to the packaging or label. Handheld or fixed barcode readers can is typically reviewed before the supplier actually ships the be used to record traceability data at all phases from receiving ingredient, the supplier can be notified of any non-compliingredients to customer shipments. Currently, RFID is more expensive than barcoding and not ance before the ingredient is shipped. widely used. However, RFID costs are going down, and usage is now increasing. Improve relationships with consumers Consumers have a growing interest in the food they eat. This ROI on your investment interest presents an opportunity for processors to increase the While ERP allows processors to satisfy regulations, it often does quality of their relationships with consumers. The traceability not extend to more advanced functions that can produce addi- system and the vast amounts of information that can be genertional ROI. “I think the real issues are how granular companies ated about the product have value for curious consumers. For are getting on traceability and the level of complexity in the example, consumers in some stores can wave their Smartphone manufacturing operations,” states Littlefield. “If companies just above an apple or orange and learn instantly where it was want to comply with one-up, one-down and lot-level traceability grown, who grew it and whether it has been recalled. They can to a 24-48 hour response time, I think ERP can work. If compa- even contact the farmer. nies want to do end-to-end, item-level, real-time traceability, they That is the case with Kroger’s new Fresh Selections line need ERP plus extended applications from the ERP vendors or of fresh salads. “Food safety is a top priority at Kroger,” says third-party, best-of-breed applications, such as quality manage- Joe Grieshaber, Kroger’s group vice president of meat, seament systems, manufacturing operations management, product food, deli and produce departments. Part of grocery chain’s lifecycle management and supply chain management.” “Quality You Can Trace” program includes new technology “ERP provides for the low-cost collection of traceability infor- on packaging that enables customers to learn where the mation,” says Jack Payne, vice president, enterprise software, produce was grown. Leveraging technology from HarvestCDC Software (formerly Ross Systems). “But the key issues are Mark packaging for Kroger’s Fresh Selections line includes how easy and effective the system is in reacting to an incident, a unique 16-digit code to enable shoppers, using a Smartand how the traceability data can be leveraged to improve the phone or website, to learn more about the salad’s origin, business.” This also has the effect of improving product formula- packing location, ingredients, date and time of packing, and tion, quality, cost, supplier performance and other areas. provide feedback online. ❖ Product improvements can be identified by connecting quality information with trace & track data. This allows the quality For more information: department to look at cause-and-effect relationships between the Matthew Littlefield, Aberdeen Group, 617-854-5204, actual specs of incoming ingredients and the resulting characteris-
[email protected] tics of a produced batch. Jack Payne, CDC Software, 770-844-0595,
[email protected] A vice president of supply chain for a mid-sized “secret sauce” Marc Simony, TraceGains, 303-450-9009,
[email protected] processor states his solution from TraceGains focuses on ingredi- Elliott Grant; HarvestMark; 866-768-7878;
[email protected]
Food Industry Strategic Actions
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TECH UPDATE: ENERGY-EFFICIENT REFRIGERATION Kevin T. Higgins, Senior Editor
` Ammonia compressors cast a lot of latent heat in engine rooms, but it’s often too low grade to justify a heat recapture system. Source: Shambaugh & Son.
Chilling on the cheap
`
There’s no complacency when it comes to driving down operating costs for food companies’ refrigeration systems.
I
n food processing, thermal transfer is like gravity: What goes up must come down. For many liquids and solids, down is somewhere south of 5°C/40°F, making refrigeration a core process. Freezing and cooling finished goods require energy, and better managing energy inputs is a priority. Green initiatives, lean programs and rising utility costs are prodding manufacturers and their supply partners to consider alternative approaches that boost thermal-transfer efficiencies. Whether the objective is to lock in positive attributes with freezing or preserve fresh food at refrigeration temperatures, innovative technologies are finding a receptive audience. Hydro cooling is a case in point. Refrigerated soups, side dishes and other commissary-style
products traditionally use refridgerated air at -10°F to lower the temperature of packaged foods below 40°F. Management at Lima, OH start-up Kettle Creations were inclined to go that route two years ago when local authorities ruled out an anhydrous ammonia system because of the close proximity of a heart clinic. The project engineer had a better idea: Why not leverage the superior heat-transfer of water to lower energy demand? Campbell Soup pioneered the process two years earlier at its StockPot division (see “Soup’s on at Stockpot,” Food Engineering, December 2008) when it installed four spiral coolers from Coastline Equipment Inc. Concluding what worked for soup in Everett, WA should work for mashed potatoes in Lima, Kettle’s owners opted for hydro cooling.
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TECH UPDATE ` Thousands of spray nozzles deliver cold water to the surfaces of mashed-potatoes packages in a spiral cooler at Kettle Creations. The hydro cooling system offers efficiency advantages over air chilling. Source: Coastline Equipment Inc.
About 3,000 stainless steel nozzles spray cold water directly on 170°F filled containers as they wend their way down the 30-tier spiral, according to Rene Janzen, sales engineer at Bellingham, WA-based Coastline, spraying 4,000 gallons a minute. A treatment system filters, ozonates and recirculates the water. Dwell time is 90 minutes. The process is gentler on the product than frigid air, Janzen maintains, and cold air can turn the corners of the packages brittle and susceptible to cracking. General contractor Keith Pohlman, president of All Temp Refrigeration Inc., Delphos, OH, plumbed the spiral system to a centrifugal chiller and added another energy enhancement: a
heat exchanger that extracts latent heat from the containers and reuses it to heat the floors. Pohlman’s chiller uses 134a refrigerant, the replacement for the chlorofluorocarbon (CFC) R22 (see related story below). The ozone depletion caused by CFCs led to a worldwide ban on Freon production, and programs like the EPA’s GreenChill that encourage retailers to find replacements for CFCs and hydrochlorofluorocarbon (HCFC) are gaining steam. Critics like Bruce Badger, president of the International Institute of Ammonia Refrigeration, maintain “the new refrigerants being concocted to reduce ozone depletion are significantly less efficient” than the coolants they replace. An EPA spokesman sharply disagrees, pointing out “the energy-efficiency of a refrigeration system depends on many factors.” Hawaiian inventor Richard Maruya recently gained EPA approval for HCR188c, the first pure hydrocarbon refrigerant. In a comparison with 134a, Maruya demonstrated his refrigerant draws 48 percent less power and requires only one-fourth the charge. Maruya targeted automotive air conditioning and home refrigerators for his blend of propane, butane and other hydrocarbons, which carries the ASHRAE designation R441A.
Cap-and-trade for refrigerants Market-based incentives to reduce greenhouse gas (GHG) emissions have, at best, an uneven track record, but proponents of an offset program targeting ozone-depleting refrigerants are cautiously optimistic about the prospects for San Francisco-based EOS Climate’s cap-and-trade program, scheduled to commence January 21, 2012. EOS focuses on the chlorofluorocarbon (CFC) segment of the carbon-reduction market. Those refrigerants contain up to 11,000 times the ozone-depleting potency of carbon dioxide. They include CFC-11 and CFC-12, commonly known as Freon. Voluntary trading in CFC credits is off to a slow start, with 1.14 million metric tons of a potential 214 million metric tons in California over the next nine years traded, but in December, the California Air Resources Board (CARB) designated CFCs for trading in carbon credits under the cap-and-trade program established under the California climate change program. In April, Cargill Inc. became EOS’s financial and marketing partner for the tradable emission credits it will generate from destroyed CFCs. “We needed a compliance market, and CARB has given us one,” says Saskia Feast, EOS’s vice president-business development, “and with Cargill’s strategic financing and
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innovations in carbon trading, we will greatly increase the removal of potent global warmers.” “Hopefully, California will be the anchor for a much larger trading area,” says Arjun Patney, carbon market strategist with Minneapolis-based Cargill. Several Canadian provinces and a few Western states are expected to join California later in cap-and-trade under the Western Climate Initiative. In the near term, California sites generating more than 35,000 metric tons of GHG a year will have to either lower emissions or buy offsets; included in that group are 34 food facilities. One of their carbon-credit options will be those traded by EOS and Cargill. As a result, any food or beverage company in the country will have the option of retiring a leaky Freon-based cooler and verifying its destruction through EOS, then receive cash from the buyer of the resulting credit. “A fairly limited quantity of these refrigerants gives you a large carbon credit,” Patney points out. The intent is to give companies a financial incentive to destroy CFCs rather than turn old systems over to salvage operators, who then resell the Freon to people who need to recharge their obsolete Freon systems. It also should drive up the price for recycled CFCs.
BELRAY.COM
TECH UPDATE
` High-efficiency fluorescent fixtures have been installed in many plants and warehouses in recent years, but rapid advances in LED lighting (inset photo) are making LED technology the preferred option, particularly in food freezers. Source: Sitka Enterprises.
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Engineers have greeted his coolant with skepticism, particularly over flammability issues, but Maruya insists the refrigerant’s small charge “makes the risk assessment a nonfactor.” To prove the skeptics wrong, he plans to charge a 50-ton system outfitted with a safety valve to automatically lower pressure in the event of a leak at the state fairgrounds in Sacramento, CA this summer. Big chill’s go-to option For large spaces, mechanical refrigeration using anhydrous ammonia is the low-cost choice, with coolant costs a fraction of those for halocarbons. Safety concerns dogged installations in decades past, and while food companies are comfortable with the technology, a spate of large-scale ammonia releases and lethal accidents in recent years has put safety back in the limelight. In the space of three months in 2009, three ammonia releases involving human fatalities occurred, including a line rupture that killed one worker and hospitalized four others at Mountaire Farms poultry plant in Lumber Bridge, NC. Within that time frame, a gas explosion and subsequent ammonia release at ConAgra’s Slim Jim plant in Garner, NC killed two and sent 38 to area hospitals, four in critical condition. Two more fatalities at a Minnesota fertilizer plant later that year made 2009 one of the worst years on record for ammonia safety. Ammonia’s reputation received another hit in August, when a roof pipe leaked a plume of
June 2011 | Food Engineering | www.foodengineeringmag.com
ammonia at Millard Refrigerated Services cold storage in Mobile, AL. More than 120 people were sickened and six hospitalized, at least one in intensive care. Ninety percent of ammonia produced in the US is used as fertilizer, according to an analysis of ammonia releases in the state of Minnesota over a 10-year period. Not surprisingly, agriculture accounted for almost half the period’s 459 documented releases. Refrigeration systems accounted for 27 percent, the second-leading cause and far ahead of meth labs, the third mostfrequent source. “Our customers are getting very serious about the safety of their refrigeration systems,” reflects Neil Horn, vice president-refrigeration at Stellar. Secondary fluids such as glycol are being paired with ammonia in some cases, with ammonia loops constrained to the engine room while the secondary refrigerant courses through the processing area. In a recently completed project, Horn oversaw the retrofitting of a cascading system at a supermarket distribution center, with carbon dioxide delivering cold air after exchange with ammonia. In 2003, Stellar engineered a CO2/ammonia cascade system at Nestlé’s Jonesboro, AR Stouffers plant, a 525,000-sq.-ft. installation that was believed to be the world’s largest. The higher saturation pressure of CO2 was seen as an energy-efficiency advantage at temperatures of -40°F, an extreme seldom applied in food storage. As a result, only “a couple dozen, maybe three dozen” cascade systems have been installed in North America, he estimates. But sustainability programs add luster to cascade, and while the financial case is difficult to substantiate, Horn is convinced cascade is more energy-efficient even in partial-load situations than ammonia-only. “If you wanted to build a 100,000-sq.-ft. freezer, the CO2 cascade system will not be any more expensive than an ammonia system,” he adds. “In fact, we have found it to be 5 to 10 percent less.” Bolstering his position is US Cold Storage, which has built six warehouses using CO2 cascade refrigeration systems in recent years. “Carbon dioxide cascade refrigeration systems are proving to be more efficient, simpler to maintain and safer to operate than typical two- or singlestage ammonia refrigeration system,” the company states on its web page. Even if initial capital requirements push out ROI a year or two, “it falls into the category of the right thing to do,”
TECH UPDATE says Horn, and a growing number of companies “are willing to do the right thing and spend additional money.”
Factors in Anhydrous Ammonia Releases
Old technology, new applications 1.3% High-pressure heat pump screw compressors 11.3% to capture and reuse waste heat are being commercialized by Emerson Climate TechEquipment failure 57.7% 9.4% nologies’ Vilter unit, but the added expense Human error 20.3% might be better invested in boiler economiz57.7% Intentional 9.4% ers and other heat reuse options, Horn sug20.3% Weather related 1.3% gests. With conventional compressors, waste Unknown/other 11.3% heat is fairly low grade, though The Dennis Group’s John Hobden says those types of energy-efficiency projects are becoming common. Even more popular, the mechaniSource: Minnesota Department of Health incident analysis, 1995-2005. cal engineer says, are VFDs on compressors, evaporators, condensers and fans. Heat recovery was not part of the engine room design Tom Aurich, refrigeration group manager at Shambaugh & Son, Fort Wayne, IN, concurs. at a recently completed two-stage refrigeration system “Years ago, you never saw VFDs on compressors,” he says. installed at Unilever’s Owensboro, KY plant, nor is it likely Harmonic frequency issues and other concerns often were in a much larger installation at Unilever’s ice cream facility cited, but the real issue was cost. Today, VFD costs have in Covington, TN, where 17 compressors and 11 evapoplummeted, and paybacks are calculated in months instead rative condensers will power a 6,500-ton refrigeration of years. system. “The quandary with heat recovery is storing the
When It's Your Can
On the Line…
Allpax provides peace of mind for you and your retort room. We handle every kind of static and agitating retort process mode (even Shaka®) and just about any container you can throw at us (even pouches). But that's only the beginning. Our retort controls are the best in the business, helping you through all your food safety initiatives.
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See Food Master, p. IFC 14
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Buhler Automation − traceability at its best. Buhler offers an integrated automation solution featuring functions entirely tailored to U.S. market needs. WinCoS.r2 is based on industrial market leading products and provides top safety in terms of quality, product traceability and operating reliability. The scalable and expandable automation system gives you the flexibility you need in a dynamic market. And it all comes with a 24/7 support. Everything you need, exactly as you need it.
Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, 763-847-9900
[email protected], www.buhlergroup.com
Innovations for a better world.
TECH UPDATE ` Hydraulic lifts raise the freezer top and provide easy access for sanitary clean-up of Air Liquide’s cryogenic freezer, helping to lower the unit’s energy footprint. Source: Air Liquide Industrial US.
water until you need it,” Aurich reflects. Nonetheless, more plate and frame heat exchangers are being incorporated in designs. “Everybody wants to be green,” he says. Among the green wannabes is WalMart, which made energy conservation a priority when engineering a 400,000-sq.ft. perishable food distribution facility last year in the Alberta, Canada. Virginia Garbutt, director-strategic net-
work planning and continuous improvement at WalMart Canada, called it the most ambitious sustainability-driven greenfield construction undertaken by the retailer when she recently spoke at ProMat 2011 in Chicago. “Sustainability is no longer an option; it’s part of your job description,” said Garbutt, though a solid ROI is expected. A conventional refrigerated DC was built in eastern Canada the prior year and served as a benchmark for evaluating the Balzac, Alberta DC. Part of the DC’s energy savings will come from LED lighting that was installed in freezer areas. LED added $486,000 in incremental costs, Garbutt says, but they are 75 percent more efficient than fluorescents. “They’re durable,” she adds. “The bulbs are expected to outlast our building.” Savings of $129,000 a year on replacement bulbs alone will speed the payback. T-5s were used throughout the previously built warehouse, and area lights are constantly on because of the delay firing the tube in extreme cold. With LED, lighting is instantaneous, and the absence of any waste heat is a plus in a freezer. The spectrum of light produced appears dull, but
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masosine.com
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Bredel
Watson-Marlow
June 2011 | Food Engineering | www.foodengineeringmag.com
See Food Master, p. 129
800-282-8823
“it’s brighter than you think,” she says, adding insects can’t see the light and are not drawn to it. “ WalMart is not against taking risk ,” obser ves Bob Catone, general manager of Guth Lighting in St. Louis, and the biggest risk in LED is rapid obsolescence. “There may be a gotcha mode that nobody’s figured out yet” in the technology, but Catone believes LED soon will be dominant in freezers and elsewhere. R&D investments in metal halide and fluorescent have ended, and TV manufacturers focused on LED are taking over lighting production. “It’s the only light source that likes to be dimmed and turned on and off,” he points out, adding, “the cost differential is shrinking considerably.”
not a flat surface in there,” says Braithwaite. “It’s as smooth as a bass boat.” W hether companies are committed to sustainable manufacturing or not, “wherever you can suck out a percentage of energy cost, do it,” advises Alex Daneman, CEO of Hench Controls Inc., Hercules, CA. “Too many people have their face too close to the glass” when calculating the payback from energy-efficiency in refrigeration systems. Electricity rates have doubled in some regions in the last five years. While no one can be certain what rates will do in the next five, one certainty is that they won’t go down. ❖ For more information: David Braithwaite, Air Liquide Industrial, 713-624-8000
Cryogenic freezing Sanitation considerations drove the design of a new cryogenic freezer from Air Liquide Industrial US, though Innovation Manager David Braithwaite points out faster clean-up also means less water use, fewer chemicals and reduced energy demand for hot water. Hydraulic lifts provide 360° access to interior components. Instead of being conveyed, coated and sticky IQF products float on a current of liquid nitrogen through the freezer. The surrounding shell is molded fiberglass, though all the moving parts are stainless steel. “There’s
Keith Pohlman, All Temp Refrigeration Inc., 419-692-5016,
[email protected] Richard Maruya, A.S. Trust & Holdings, 808-235-1890,
[email protected] Rene Janzen, Coastline Equipment Inc., 360-734-8509,
[email protected] John Hobden, The Dennis Group, 413-787-1785 Saskia Feast, EOS Climate, 626-840-6955,
[email protected] Bob Catone, Guth Lighting, 314-566-4550 Alex Daneman, Hench Controls Inc., 510-759-7777 Tom Aurich, Shambaugh & Son, 260-487-7751,
[email protected] Tom Horn, Stellar, 904-899-9316,
[email protected]
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See Food Master, p. 82
www.foodengineeringmag.com | Food Engineering | June 2011
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FIELD REPORTS
Optimizing walnut moisture content is a win-win-win
`
Grower/producer achieves product improved quality, energy savings and quicker turnarounds.
F
edora Farms, located in Meridian, CA, is one of the largest walnut processing facilities in the country and has succeeded in cutting its operating costs by implementing energy-efficient processing equipment. This family-run business has always put quality first and uses automation technology in several phases of walnut processing, including hulling, conveying and, perhaps most importantly, drying the walnuts and monitoring their moisture content. After the walnuts are shaken from the trees, they’re gathered and brought into the Fedora facility so processing can begin immediately. The nuts’ outer coverings are hulled, and the walnuts are then dried to 8 percent moisture content. “Quality is most important,” says Fedora Farms’ Chris Fedora. “We want to ensure that we deliver nice, healthy meat kernels at maximum weight so we can get the highest return. We also want to free up the dryers as quickly as possible so we process product faster.” Fedora enlisted the expertise of Woodside Electronics Corporation (WECO)—specialists in sort-
` (Clockwise, starting at top left): Walnuts arrive in trucks; walnuts are then placed in drying bins; Opto 22 SNAP PAC brains and I/O bring in sensor data and control drying systems (fans and burners); HMI screen from WECO allows operators to adjust critical set points, maximizing product quality and energy usage. Source: Opto 22.
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ing and automation solutions for the agricultural industry—to implement the necessary monitoring and control hardware. “Although we’re always in a rush during harvest, we only dry walnuts at a maximum temperature of 110°F,” says WECO’s Don Osias. “Any higher temperature would reduce the quality and character of the walnut’s healthy oils.” The goal is to dry the nuts to about 8 percent moisture. Over-drying can be detrimental in several ways. In addition to the cost of the unnecessary fuel and power used to run the dryer, over-dried nuts become brittle and are easily broken during handling. Additionally, if the nuts stay in the bins too long, the processing of the total crop slows, and the nuts lose moisture content and weight, which means less profit for the grower. WECO provided Fedora Farms with customdesigned, portable moisture meters and automation hardware that provide moisture information and control the dryers’ fans and burners. Opto 22 SNAP PAC brains (processors) and I/O are the key components used in WECO’s automation systems. Analog and digital input modules gather all process data and adjust temperatures and other variables. Analog and digital output modules control the air doors, fans and burners. Networked scanners collect the moisture information from each bin and send it to a PC in either text or graphics so operators know exactly how the drying process is progressing. Fedora’s automation system uses the moisture information to open and close the air door under every bin at just the right time, and start and stop the drying process. Fans and burners are shut down as soon as the nuts in the bins are dry. This makes processing faster, increases profit and saves energy. “Monitoring the moisture in those bins and having the automated door controls allows us to hit that 8 percent, shut things off and ship the product right away, which frees up more dryer space,” says Fedora. ❖ For more information: James Davis, 951-764-4748,
[email protected]
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
INDEX Allpax ..............................................................................................102 Ashworth .......................................................................................102 Atlas Copco...................................................................................103 Austin Company ..........................................................................103 Baldor Electric Company ...........................................................104 Big D Construction......................................................................104 Breddo Likwifier ...........................................................................105 Buhler Inc. .....................................................................................105 Bunting Magnetics Co. ..............................................................106 Burns & McDonnell ....................................................................106 Charles Ross & Son Corp..........................................................107 Chemetall .......................................................................................107 Dorner ............................................................................................108 Douglas Machine ........................................................................108 ElectriCities ....................................................................................109 Eriez Magnetics ...........................................................................109 Flexicon Coporation ....................................................................110 Fristam Pumps ..............................................................................110 GEA Tuchenhagen North America .........................................111 GEA Westfalia Separator, Inc. ..................................................111 Haskell Co. ....................................................................................112 Hinds-Bock Corporation............................................................112 Hixson Inc. .....................................................................................113 JAX ..................................................................................................113 Kason Corporation ......................................................................114 Lubriplate Lubricants Co. ..........................................................114 Machine & Process Design Inc. ..............................................115 Masosine Process Pumps .........................................................115 Material Transfer & Storage .....................................................116 MEPACO........................................................................................116 Mueller ...........................................................................................118 National Bulk Equipment ...........................................................117 Omega Engineering Inc. ............................................................118 Parker Balston ..............................................................................119 Perfex ..............................................................................................120 Power Engineers..........................................................................120 Reid Supply Company ................................................................121 Reiser ..............................................................................................121 Schenk Accurate .........................................................................101 SEW Eurodrive..............................................................................122 Siemens..........................................................................................122 SlipNOT Metal Safety Flooring .................................................123 Spraying Systems Co..................................................................123 SPX ..................................................................................................124 Stonhard ........................................................................................124 Thermo Scientific .........................................................................125 Triple S Dynamics, Inc. ...............................................................126 Urschel Laboratories, Inc. .........................................................126 Woodward & Curran ..................................................................127 Zeppelin Systems ........................................................................127
Schenck AccuRate Schenck AccuRate is a complete solutions provider for feeding dry ingredients or additives in food processing applications. Focusing on our customer’s needs we’ve invented and continue to advance bulk solids material handling products and systems that have a proven track record for accuracy, reliability, price efficiency, and quality. Our award winning MECHATRON® feeder is used in food manufacturing applications where the need to feed materials like flours, colors, preservatives, fruits, spices, and sweeteners are required. Offered with either a Coni-Flex™ flexible hopper or in all stainless steel the feeder has the unique ability to be disassembled from the non-process side eliminating the need to remove upper extension hoppers, bins, bulk bags, or IBC’s for cleaning and maintenance. 3-A sanitary models with wash down motors, electropolished frames, and FDA accepted white polyurethane internal feed hoppers are also available. In addition to the MECHATRON® feeder, Schenck AccuRate is trusted by food manufacturers throughout the world for its vibratory feeders, weighbelt feeders, solids flow meters, bulk bag discharging systems, and controls. Whatever your food manufacturing process, you can be assured that Schenck AccuRate will achieve the optimum feeding solution.
Contact: Schenck AccuRate 746 E. Milwaukee Street Whitewater, WI 53190 800-558-0184 Fax: 262-473-4384 www.accuratefeeders.com
[email protected]
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2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Allpax Products
Ashworth Bros., Inc.
The Allpax Advantage Allpax Products manufactures a complete range of severe duty sterilization and material handling machinery for food, beverage and pharmaceutical companies. From fully automated retort rooms to individual retort room components, our comprehensive line of turn-key equipment has helped us become one of the world’s leading sterilization solution providers. Our Automated Batch Retort System automates all functions of the retort room with easy-to-use controls and software, removing the complexity that usually accompanies the retort process. We also back our solutions with expert project management and installation from start to finish, full factory acceptance tests and 24/7 support to reduce potential production downtime.
Ashworth Bros., Inc. - Innovating for Efficiency Marked by more patents in the industry than any other belting manufacturer, Ashworth Bros., Inc. continues innovating conveyor belting technologies that increase efficiency for food processing industries. Ashworth is the only belting manufacturer that utilizes both metals and plastics to engineer conveyor belts that increase throughput and minimize downtime for the most demanding applications. Omni-Pro® 075, 100, & 120 Belts minimize cage bar wear, maintenance costs and downtime in the most demanding hightension spiral applications. Capable of withstanding tensions up to 400lbs. and rated for 100,000 cycles, versus competitor ratings of only 50,000 cycles, Omni-Pro delivers unmatched strength and reliability. The patent pending 360º “zero-tension” welds increase strength while the patented coining process prevents break-in wear, reduces belt elongation and increases belt life. The patented “protrusion leg” design eliminates welds from contacting spiral cage bars, enabling the belt to run smoother with less system wear. Advantage Belts are the industry’s only plastic spiral conveyor belts that are USDA accepted. Designed on the strength of stainless steel rods, Advantage belts are guaranteed not to sag. The plastic mesh offers the greatest open area, increasing airflow and delivering the shortest dwell times. Advantage belts withstand tensions up to 300 lbs for 100,000 cycles, making it the industry’s strongest plastic spiral belt. Cleatrac® belts travel around the smallest nose bar diameters in the industry (down to 0.20 inch) to accurately transfer small products, minimize damage and improve profits. Ashworth guarantees positive sprocket engagement with the Cleatrac® Belt & Sprocket System, ensuring precise product conveyance. The balance weave design is extremely durable and available in a variety of mesh configurations to provide proper product support and airflow for a wide range of applications. Standard widths are stocked for immediate delivery. Ashworth Factory Service offers a full range of engineering and maintenance services for stacker and lotension spiral conveyors, including trouble-shooting, belt installation, system upgrades, refurbishment, and relocation. On-call 24/7/365, Ashworth Factory Service Experts provide you peace of mind with decades of experience, quality workmanship, and comprehensive belting support.
Products and Solutions Retorts: Allpax offers solutions for every type of retorting system available in sizes ranging from lab to production scale. We can handle nearly all containers in the marketplace today including challenging designs like pouches and fragile containers. We provide retort and sterilization solutions for the following processes: • Water Immersion • Saturated Steam • Steam-Air • Spray • Water Cascade • Rotary • Gentle Motion • Shaka® Material Handling: Allpax provides solutions for nearly any material handling and automation needed between sealing and packaging, including basket loaders and unloaders, conveyers, shuttles and other equipment going into and out of the retort room. Our advanced software, sensor and tracking systems allow our customers to manage a large-scale retort room with only one or two operators while preventing accidental distribution of under-processed products to market.
Contact: Allpax Products 13510 Seymour Myers Blvd. Covington, LA 70433 985-893-9277 www.allpax.com
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Contact: Ashworth Bros., Inc. 450 Armour Dale Winchester, VA 22601 Phone: 540.662.3494 or 800.682.4594 Fax: 540.662.3150 or 800.532.1730 E-mail:
[email protected] Website: www.ashworth.com
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Atlas Copco Compressors LLC
The Austin Company
Atlas Copco Compressors has a focus on exceeding customer needs with a culture built on ongoing interaction, long-term relationships, and a commitment to understanding each customer’s process and objectives. As a result, every compressed air solution we create helps customers operate with greater efficiency, economy, and productivity.
The Austin Company Food & Beverage Group is an in-house team specializing in planning, designing and implementing safe, efficient and economical food and beverage facilities. From new construction to renovations and expansions, we offer a dedicated team focused exclusively on the food and beverage industry. Our services include:
Products offered include: • Oil-Free Compressors • Oil-Injected Compressors • Compressed Air Dryers and Filters • Nitrogen Generators • Compressed Air Piping • Compressed Air Controls and Monitoring Systems • 24/7 Service At Atlas Copco, our mission is to continue to bring sustainable productivity through safer, cleaner, more energy-efficient compressed air technology. Our unwavering commitment is to be First in Mind – First in Choice® for all your compressed air requirements.
• Planning • Economic Analysis • Site Location • Architecture/Engineering • Process Engineering • Packaging Systems Services • Design-Build • Construction Management • Installation & Start-Up Our extensive experience includes successfully completed projects for all types of operations — baking and snack foods; beverages; condiments; confectionery; diary; frozen foods; grains; fish; produce; and specialty items. We have successfully implemented projects throughout the world including: • Manufacturing and Production Facilities • Bottling Plants • Formulation and Packaging Plants • Research Laboratories • Bulk Storage Warehouses • Automated Distribution Centers
A KAJIMA USA Company Contact: Paul Humphreys Vice President Communications and Branding Atlas Copco Compressors LLC 1800 Overview Drive Rock Hill, South Carolina 29730 USA Phone: +1 (803) 817-7479 - Fax: +1 (803) 817-7440 E-mail:
[email protected] Visit Atlas Copco at: www.atlascopco.us
Contact: The Austin Company Food & Beverage Group Bob Graham, Vice President Food and Beverage 404-564-3964
[email protected] www.theaustin.com
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2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Baldor Baldor Electric Company, headquartered in Fort Smith, Arkansas, designs, manufactures, and markets the broadest line of industrial energyefficient electric motors, power transmission products, adjustable speed drives, linear motors, motion control products, gear products, industrial grinders and generators. 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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Big-D Construction All Build, No Bull In your business, food is more fragile than fine china. Even the most confident contractor can become a bull in a cheese shop without fully understanding the critical points of control inside your dairy or food facility. A Language All its Own. Food and beverage facilities are built on a language of their own — where critical control means systematically identifying, assessing and controlling health hazards within the food chain — from construction to production. We speak it. Without a hint of an accent. In fact, we could spend the better part of a day talking about the success of our services and systems. Suffice it to say, that these proprietary systems have made Big-D one of the top 10 food and beverage contractors in the nation for the last 10 years. And that’s saying a mouthful. The Bread and Butter of your Building. Known for crafting sophisticated food and beverage plants, distribution centers, low temperature facilities, milk and cheese plants, and a variety of distribution and processing facilities, Big-D is considered the bread and butter – even the cream – of the food and beverage construction industry. Big-D also gives you more value for your green. Our portfolio includes a wealth of certified, silver, gold and platinum LEED® facilities. Menu of Capabilities Dairy Processing Plants Food & Beverage Facilities Remodels Expansions Additions Low-Temp Facilities Distribution Facilities Tilt-up Construction Green Field Brown Field LEED® / Sustainable Service Projects Maintenance Support Manufacturing Facilities Strategically Planned Shutdown Support Services
Contact: Forrest D. McNabb, CPE, Senior Vice President 404 West 400 South Salt Lake City, UT 84101 801-415-6000 www.big-d.com
[email protected]
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Breddo Likewifier
Buhler Inc.
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. 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 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
The Buhler twin-screw extruder POLYtwin™ completely fulfills process requirements such as high torque, screw speeds and pressure, and thanks to its modular design, this highly sophisticated machine is extremely flexible in application. Innovative extrusion processes without limits Buhler is a global leader in the field of process engineering, in particular production technologies and services for making foods and engineering materials. With our extensive extrusion know-how and passion for customized solutions, Buhler strives to generate added value and success. With the addition of Aeroglide to the Buhler group, we now Buhler offers tailored customer offer one of the most complete trainings and workshops, either production lines available on site or at Buhler’s extrusion anywhere. From raw material pilot plant. handling, cooking and shaping through extrusion and drying of finished products - from breakfast cereals and snack foods, modified flours, starches and texturized proteins to premium pet food and treats. Our full line of equipment, combined with in-house process engineering and unrivaled after sale support, equals customized solutions without limits.
Contact: Buhler Inc. 13105 12th Ave. N., Plymouth, MN 55441, USA Contact name: Christoph Naef, Manager Extruded Products E-Mail:
[email protected] Phone: +1 763 847 9243 Fax: +1 763 847 9902 www.buhlergroup.com
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Bunting Magnetics
Burns & McDonnell
Protect Your Product Purity, Safeguard Your Machinery!
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 and food defense, 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.
The combination of our DCM Conveyor and Metron C Metal Detection provides our customer peace of mind with superior metal detection within your manufacturing process. These units can be custom built to exact specifications – ready for installation. The DCM Conveyor,which as a Nema 4x Rating for pressure washdown protection, features: • Direct drive reducers and motors • Controls with start/stop buttons • Adjustable height leveling pads or castors • 300 series stainless steel tubing frame • Modular belting • Multiple reject options available The Metron “C” Metal Detector, a one piece tunnel-style triplecoil detector, surrounds the DCM conveyor belt to sense metal contaminants. It features: • Waterproof construction (Nema 4x Rating) • Automatic product tracing • Temperature compensation • Built-in-digital event counter • Epoxy-filled search head • Serial interface (rs-232) • Multi-level password protection
Contact: Contact name: Rod Henricks, Product Manager – Metal Detection Address: 500 South Spencer Road, Newton, KS 67114 Phone: 316-284-2020 Fax: 316-283-3408 URL: www.buntingmagnetics.com e-mai:
[email protected]
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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 ArchitecturalEngineering-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.
Contact: Caroline Cooper Burns & McDonnell 9400 Ward Parkway Kansas City, MO 64114 816-822-3831
[email protected] www.burnsmcd.com/fcp
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Charles Ross & Son Company Sanitary Mixing & Blending Serving all the process industries in virtually every industrialized country around the world, Ross has led the evolution of sanitary rotor/stator mixers, multi-agitator mixers and granulators, vacuum homogenizers and sanitary blenders. Ultra-High Shear In-Line Mixers
In the USA alone, Ross operates five plants, a Test & Development Center, an analytical laboratory and a vigorous R&D program. Overseas, Ross sanitary equipment is manufactured in three of our own plants, and in numerous other plants under license. Products and Services
Sanitary Ribbon Blenders
Ross can answer virtually all of your needs for specialty vessels and mixing/blending equipment for sanitary applications.
• Ultra-High Shear In-Line Mixers • Batch & In-Line Rotor/Stator High Shear Mixers • New Powder/Liquid Injection Technology • Multi-Agitator, Change-Can Mixers • Fully Integrated Vacuum Mixer Homogenizers • Double Planetary Mixers • Ribbon and Vertical Cone Screw Blenders • Complete Fabrication Capabilities • Advanced Control Systems • Test & Development Center Call Ross for answers to all of your mixing and blending needs, anywhere in the world.
Contact: Charles Ross & Son Company 710 Old Willets Path Hauppauge, NY 11788 1-800-243-ROSS Overseas: 631-234-0500 Fax: 631-234-0691 E-mail:
[email protected] www.mixers.com
Chemetall To ensure the reduction and elimination of contaminates, rely on Chemetall. We have provided superior sanitation solutions to the food industry for almost one hundred years. Our experience and expertise have resulted in the creation of over 300 products to meet the industry’s specific needs, including: • Caustic Cleaners • Chlorinated Cleaners • Floor Cleaners • Hand Cleaners • Sanitizers • Acid Cleaners • Defoamants • Non-Caustic Cleaners • Conveyor Chain Lubricants • Foam Cleaners • Rinse Additives • CIP Cleaners • General Cleaners • Water Treatment By working closely with our customers, Chemetall is also able to provide equipment tailored to specific processes such as: • Chemical Control Systems • Data Acquisition • pH Monitoring • Central High Pressure • CIP Control • COP Washing • Chemical Proportioning • Conveyor Lubrication • Conveyor Cleaning • Bulk Tank Storage • Foam Cleaning • Floor and Door Sanitizing Food industry customers enjoy the many benefits of Chemetall’s customized sanitation programs which include time, energy and manpower savings. Allow us to complete a complimentary evaluation of your current process so that we can create a complete customized sanitation solution that incorporates formulations, equipment, employee training, and technical support. With Chemetall, the only ingredient added is clean.
Contact: Michael Brancato, Director, Food/Non Metal Chemetall 675 Central Avenue New Providence, New Jersey 07974 Toll-Free: 800-526-4473, ext. 2444 Phone: 908-464-6900, ext. 2444 Cell: 609-865-0337 Fax: 908-464-7914 E:mail:
[email protected] www.chemetallamericas.com
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Dorner
Don’t Get Left in the Dust We’re excited to help customers Move Fast and Smart with our new DustPruf® conveyors with smooth-sided SmartSlot™ technology designed for cleaner production while maintaining flexibility. Dorner’s new 2300 and 5300 Series conveyors are part of the new DustPruf family of conveyors. They bring the same industry-leading ease of automation, flexibility, and performance that customers expect from Dorner conveyors. Plus, our SmartSlot technology is designed into the frame. The SmartSlot provides all the integration and add-on capabilities of a T-slot without the inherent drawback of debris collection. Customers can use the patent-pending SmartSlot system of self-tapping screws and a cordless drill to quickly attach any guiding and automation accessories necessary for their application. A small indentation on the conveyor’s frame directs customers to the best place to install these additional components. As implied by their name, the DustPruf 2300 and 5300 Series are essentially “dust proof,” thanks to a streamlined frame design that virtually eliminates all catch points where particulates or debris can collect. The DustPruf design delivers a cleaner and more efficient manufacturing process. Dust from corrugate or the packaging process will no longer affect conveyor performance. Granular or fine particle products that often become airborne will no longer fall back into collection areas on the conveyor. Packaging environments will simply be cleaner.
Douglas Machines Corp. Douglas Machines Corp. offers a full line of automated washing and sanitizing equipment for all containers commonly used in food processing and distribution industries. Over 80 standard models exist to quickly and efficiently clean pans, trays, moulds, scale parts, screens, pallets, lugs, totes, racks, smoke trucks, bins, vats, barrels and buckets. Batch and continuous cleaning systems are available to clean several hundred to several thousand containers an hour. Each model is designed to save labor, water, chemical and energy, plus help you consistently meet today’s high standard if cleanliness and sanitation. Ensure an effective Food Safety Program with Douglas Washing and Sanitizing Systems. For a complete overview or for literature and specifications on a particular model, visit www.dougmac.com or call 800-331-6870 today.
Visit www.dustprufconveyors.com to learn why we are considered experts in product control and accomplish the most in the available space while minimizing product loss.
Contact: Contact name: John Kuhnz Address: 975 Cottonwood Ave, Hartland, WI 53029 Phone: 800-397-8664 Fax: 800-369-2440 URL: http://www.dustprufconveyors.com Email:
[email protected]
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Contact: 2101 Calumet Street, Clearwater, Florida 33765 Phone: 727-461-3477 or 800-331-6870 (U.S. and Canada) Email:
[email protected] Web Site: www.dougmac.com
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
ElectriCities
Eriez Feeders and Conveyors 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.
Carolina On Your Mind? ElectriCities Can Put It On Your Desk. “As easily as flipping a switch, site selection professionals can order a detailed report on North Carolina sites, from mountains to coast, that precisely match a business’s specifications,” states Brenda Daniels, economic development manager for ElectriCities of North Carolina, Inc. “All within 48 hours of a request.” The not for profit service organization represents 70+cities, towns and universities that own electric distribution systems. Using ElectriCities as an introduction to North Carolina, site search managers have a turn-key information source. “They find all the information they need in one place,” said Brenda Daniels. The process is fast, easy and entirely confidential. ElectriCities remains a partner through the entire site location process, helping companies with utility related issues, arranging site visits, and facilitating contact with local, county and state officials. Services to communities and their corporate citizens go far beyond producing the right information. This innovative agency has developed two Prime Power Parks in the Cities of Albemarle, located in the Piedmont’s lake country; and in Gastonia, just off I-85 fifteen miles from Charlotte. “These new industrial parks are NC Certified Sites with 4 MW of on-site backup power generation,” Daniels said. “If a company has a critical operation that can’t risk a power outage, they have a backup available, and don’t have to spend the money to purchase a generator.”
Contact: To learn more, call Brenda Daniels at ElectriCities toll-free 1-800-768-7697 ext. 6363 or mobile 919-218-7027; email
[email protected]; or visit www.electricities.com.
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
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Flexicon Corporation
Fristam Pump 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. 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 no-disassembly-required “True CIP”. Its balanced rotors and large-diameter shafts make it durable and reliable.
Bulk Food Handling Equipment and Systems Flexicon Corporation is a world leader in the design and manufacture of bulk food handling equipment and custom-engineered plant-wide systems that transport, discharge, fill, weigh, blend, deliver and/or feed a broad range of powder and bulk foods— free- and non-free-flowing products that range from sub-micron powders to large particles, including ingredients that pack, cake, smear, plug, break apart or fluidize, with no separation of blended products. Individual equipment and integrated, automated systems can source bulk food from interior and exterior plant locations, transport it between process equipment and storage vessels, weigh it, blend it, and feed it to packaging lines. Choose from dust-tight units that prevent product and plant contamination and allow thorough, rapid wash down, many of which are designed and constructed to 3-A, USDA and other U.S and international food, dairy and pharmaceutical standards. Equipment includes: flexible screw conveyors, pneumatic conveying systems, volumetric feeding conveyors, multiple delivery systems, bulk bag fillers, bulk bag dischargers, weigh batching systems, manual dumping stations, lift-and-seal/open chute drum dumpers and storage vessels. Numerous patented innovations achieve unprecedented productivity and cleanliness. Flexicon also custom-engineers automated, plant-wide bulk food handling and processing systems that integrate Flexicon equipment with that of other manufacturers. Manufacturing on four continents enables international customers to standardize process efficiency and food quality.
Contact: Flexiconporation Corporation 2400 Emrick Blvd. Bethlehem, PA 18020-8006 Tel: 888-353-9426 Fax: 610-814-0600 Email:
[email protected] www.flexicon.com
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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 loading 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
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
GEA Tuchenhagen 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. 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-b359), also the first of its kind to be authorized for 24/7 production in dairy plants. Additional services offered by GEA Tuchenhagen include concept design engineering, manifold prefabrication, plant service and customer training.
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 twitter.com/TuchenhagenNA
GEA Westfalia Separator, Inc. 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.
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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Haskell
Hinds-Bock Corporation
Haskell is an acknowledged industry leader in the design and construction of world class manufacturing facilities for the food and beverage industry. As the nation’s leader in sustainable design and construction, Haskell builds energy efficient facilities for Top 50 companies in the industry and has long been known for its innovation in design and efficiency in project execution.
Hinds-Bock Corp. is dedicated to meeting the needs of the baking industry with high-quality piston depositing equipment, pumps, icers/glazers and cake slicers. The company’s equipment ranges from small tabletop muffin depositing to high-volume industrial lines, which include tray and papercup denesters, pan oilers, large intermediate hoppers, dry ingredient depositors for toppings, servo-driven conveyors and PLC controls. 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. In addition to piston depositors Hinds-Bock manufactures servo driven pump fillers for high speed depositing and spreading of product. Hinds-Bock also manufactures servo piston depositors for automatic depositing and spreading of icings, fruits, batters and sauces. 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. 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.
The four walls and everything within Global Reach Haskell supports our multi-national customers with engineering and construction services across the globe. From our headquarters in Jacksonville, corporate offices in Atlanta, Dallas, and Mexico City, and project offices worldwide, Haskell serves our customers in North America, Latin America, Europe and Asia. Expanded Portfolio Haskell has expanded its product offerings to include both process and packaging system integration. Through organic growth and acquisition, Haskell now has a full complement of system integration engineers with years of experience in virtually every segment in the food and beverage industry. Experienced Resources Our team of over 700 engineers and construction managers are experts in project delivery for the food and beverage industry, consumer products industry and other manufacturing industries. This diverse expertise adds value to our customers as we bring technologies and approaches from a wide range of applications to the table as we search for innovative solutions to meet their business needs. Flexible Contracting At Haskell we focus on the business needs of our customers and are flexible in our approach to contracting. We are prepared to deliver complete solutions for facilities and systems under an Engineer, Procure, and Construct (EPC) contracting arrangement but will also support the customer with subsets of that approach as needed. Certainty of Outcome Our promise to our customers is certainty of outcome. Through our EPC delivery methods we are prepared to take on every aspect of project delivery and provide an end-to-end solution. We have the integrated team of professionals required to make that commitment to you and are prepared to back up that claim by taking on the risk that must be managed to achieve a successful outcome. With Haskell you can be assured we will deliver “The four walls and everything within”. Contact: Haskell - Corporate Headquarters 111 Riverside Ave. Jacksonville, FL 32202 Phone: (904) 791-4500 FAX: (904) 791-4699 www.haskell.com
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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
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
JAX INC. 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. Contact: JAX INC. W134 N5373 Campbell Drive Menomonee Falls, WI 53051 262-781-8850 Phone / 262-781-3906 Fax www.JAX.com
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Kason Corporation BULK FOOD SCREENERS, DRYERS, COOLERS, MOISTURIZERS Kason is a leading worldwide manufacturer of screening equipment and circular fluid bed dryers, coolers and moisturizers for powder and bulk food products ranging from dry or moist materials to solids-laden slurries. All Kason equipment is available in finishes to meet 3-A, FDA, BISSC and/or other US and international standards required in the food, dairy and pharmaceutical industries, as well as C.I.P./S.I.P designs for hands-free sanitizing, and quick-disconnect configurations allowing rapid disassembly for removal of components, wash-down, screen changes and/or inspection. Screening applications include classifying, sifting, scalping, de-dusting, and dewatering on a batch or continuous basis, efficiently separating solids from solids and/or solids from liquids at rates from several pounds to 50 tons per hour. Vibroscreen® circular vibratory screeners are offered in both gravity-fed and in-line-pneumatic configurations, and range in diameter from 18" to 100" (460mm to 2540mm). Models range from basic, low cost screeners available for fast shipment, to highly custom units incorporating patented Kason innovations.
Lubriplate Lubricants Company Lubriplate NSF H-1 Registered, Synthetic, Food Machinery Lubricants Food processors worldwide have discovered the many advantages of using Lubriplate’s advanced, NSF H-1 registered, synthetic food machinery grade lubricants. These advantages include; extended lubrication intervals, multiple application capability, lubricant inventory consolidation, improved machinery performance and simplified operations. Lubriplate’s complete line of NSF H-1 registered lubricants, are clean, safe and non-toxic. In fact, their use can eliminate lubrication as a potential chemical hazard in HACCP programs. Manufactured in compliance with ISO 21469 guidelines, they comply with FDA regulations 21 CFR 178.3570 and 21 CFR 172.882 for lubricants with possible incidental food contact. They meet USDA safety standards and are authorized for use in federally inspected meat and poultry plants. They are certified OU Kosher Pareve and HALAL registered. Available lubricants include; greases, gear, bearing and chain lubricants, air compressor fluids, hydraulic fluids and a variety of specialty lubricants that ensure complete plant coverage all from one supplier. All Lubriplate Lubricants come with Lubriplate’s exclusive, complimentary ESP Extra Services Package. Services include; complete plant lubrication surveys by a factory direct representative, lubrication maintenance schedule software, color-coded machinery lubrication tags and followup lubricant analysis all at no charge. Lubriplate also offers a Toll Free Technical Support Hotline and E-mail for quick answers to your lubrication questions. Lubriplate district managers have an average of fifteen years experience in the field of lubrication.
Centri-Sifter® centrifugal screeners, also offered in gravity-fed and in-linepneumatic models, can sift, scalp, and/or dewater a broad variety of dry or moist materials, including bulk foods that tend to ball or agglomerate. New models feature cantilvered shafts that allow for removal of internals, and provide vibration-free operation at high speeds under heavy loads. Kason’s exclusive line of circular vibratory fluid bed processors can dry, cool or moisturize bulk foods with unmatched efficiency because the circular design is inherently rigid, allowing materials of construction to be down-gauged, motors to be downsized and components to be eliminated.
Contact: Henry Alamzad, President Kason Corporation 67-71 East Willow St. Millburn, NJ 07041-1416 Tel: 973-467-8140 Fax: 973-258-9533 E-mail:
[email protected] Web: www.kason.com
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Contact: Mr. Jim Girard, VP Lubriplate Lubricants Company Newark, NJ 07105 / Toledo, OH 43605 Phone: 1-800-733-4755 Website: www.lubriplate.com E-mail:
[email protected]
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Machine & Process Design, Inc. Machine and Process Design was established in 1985. We have spent the last 25 years focusing on the design and fabrication of high quality equipment to meet our specific customer requirements in many industries including the food, dairy, chemical, and pharmaceutical industries. MPD has been asked by our customers to offer equipment designs that excel in sanitary applications. We have integrated these sanitary designs into our product lines, which include Size Reduction Equipment, such as RIGIMILL® Hammer Mills, Single, Dual & Quad Rotor Crushers and specialized machines such as Pasta Breakers and Granulators. We also offer a line of Material Handling Equipment such as our Sani-Trac® Conveyors, Screw & Vibratory Conveyors, Surge & Tempering Bins, Ribbon Blenders, Enrobing Drums, Gravity & Vibratory Screening Equipment, Diverter Valves, and other equipment. Machine and Process Design has partnered with many food manufacturers to develop special processing systems for their specific products. These systems along with many of our standard offerings are being utilized to help them achieve maximum processing efficiencies. We take pride in being a selected equipment supplier to the Food Industry and look forward to providing value added solutions in the future. Machine and Process Design today continues to design equipment meeting a multitude of standards such as BIISC, GMA, USDA dairy, and we pride ourselves in our ability to find sanitary solutions to your processing needs.
MasoSine Process Pumps Sine pumps: Gentle, reliable and cleanable Sine pump technology by MasoSine Process Pumps is the result of over 30 years of engineering innovation. We offer the pump of choice for thick or shear sensitive products like cheese, whole fruit fillings, soups, stews, batters, syrups, juice concentrate or even whole chicken breasts. Gentle, Low Shear Pumping Unrivaled in its ability to preserve product integrity, MasoSine has set the standard for handling large and fragile particulates without damage. Our sine pump technology maintains a constant volumetric displacement, providing a smooth flow profile without the pulsation spikes typically associated with conventional rotary lobe pumps. The gentle wavelike action of our unique sinusoidal rotor transports your product through large open pump cavities without compression, ensuring that food is not damaged during transfer. Reliable, Low Maintenance Operation MasoSine pumps have only a single shaft and single rotor. With very few parts, occasional pump overhauls can be performed in-line, often within minutes. Unlike other pump types, our pump housing has a 20 year warranty and does not require costly off-site factory remanufacturing or reconditioning. Confident cleanability MasoSine pumps are capable of being cleaned-in-place (CIP) and are certified to 3-A sanitary standards. Additionally, sine pumps are a quick and easy technology to disassemble, clean and reassemble on the spot for clean out of place (COP) protocol. Superior Suction MasoSine delivers superior suction capability, enabling processors to handle highly viscous products while eliminating process or pump damage from cavitation.
Please check out our product offerings at: www.mpd-inc.com
Contact: Machine & Process Design, Inc. Toll-free US: 877-224-0653 763-427-9991 www.mpd-inc.com
Contact: MasoSine Process Pumps Watson-Marlow Pumps Group 37 Upton Technology Park Wilmington, MA 01887 800-282-8823
[email protected] masosine.com
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Material Transfer
MEPACO
CORPORATE DESCRIPTION: Material Transfer is an industry leader in the custom design and manufacture of material handling equipment and systems for dry powders and bulk solids. A unique combination of application focused engineering, award winning designs and exclusive features results in equipment that offers class leading quality, value, durability, ease of use, and performance. Equipment is fully assembled, inspected and factory tested prior to shipment to ensure reliable performance, and customer satisfaction. TECHNOLOGIES: Over 95% of the equipment Material Transfer manufactures is custom designed for a customer’s particular application requirements. Material Transfer has a team of talented engineers and the latest 3D computer software for equipment design, professional metal fabricators and machinists with the latest fabrication and CNC machining technologies, and an experienced team of machine assemblers to build its products. MAJOR PRODUCTS: Material Transfer’s product line includes: • Material Master™ Bulk Bag Conditioners - Quickly and safely return hardened materials to a free-flowing state. • Material Master™ Bulk Bag Dischargers - Feature patented technology for clean, dust-tight discharge of your materials. • Material Master™ Bulk Bag Fillers – From economical 4-post units to fully automated PowerFill™ filling systems. • Container & Drum Dischargers – Discharge any size container at heights to 40’, dust-tight Lift & Seal System™ or open discharge. Patented Control-Link Rotation System™ for 180° rotation. • Integrated Systems – To meet your application requirements.
Contact: Material Transfer 1214 Lincoln Road Allegan, MI 49010 Phone: 800-836-7068 Fax: 269-673-4883 Email:
[email protected] www.materialtransfer.com
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CONSIDER THE SOURCE when it comes to single-source system integration. Since 1932, Mepaco has been a world leader in cooking, thermal processing, blending, grinding, and material handling solutions. Mepaco offers cutting edge designs, backed by engineering and manufacturing experts with vast experience in small and large scale system integration. As pioneers in the food processing industry, Mepaco delivers reliable processing equipment to serve the meat & poultry, prepared foods, baking & snack, dairy, and petfood industries. Some of these include: • ThermaBlend Cookers • Continuous Cookers • Vacuum Stuffers • Pumping Systems • Grinders • Mixer-Blenders • Dumpers • Belt Conveyors • Dough Kibblers • Ergonomic Lifts • Screw Conveyors • Mixer-Massagers Mepaco’s support services include in-plant trial programs, equipment/ system start-up, and customer operator and maintenance training. Technical services engineers are available to answer questions, offer advice, or to be at a customer’s plant at a moment’s notice. Genuine Mepaco spare parts, with troubleshooting expertise, are available 24/7. The company’s transportation department can organize the packing and shipping of equipment and systems using its own fleet of trucks or its network of freight providers to ensure a safe efficient delivery.
Contact: MEPACO 920-356-9900 email:
[email protected] www.mepaco.net
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Sanitary Systems Design Compliance-ready Bulk Material Handling for Regulated Processes and Practices Whether designing, building, and commissioning a complete processing line or integrating NBE equipment into a legacy operation, the objectives for NBE are the same: ensure the regulatory compliance of all NBE equipment, align NBE equipment operation with required process standards and protocols, speed systems start-up, simplify inspections, protect operators, and increase total process contribution. The full line of NBE sanitary, compliance-ready bulk material processing and packaging systems includes: bulk bag fillers and bulk bag unloaders, bulk container fillers and container dumpers, material mixing and conditioning systems, NTEP-certified (Cert. No. 07-108) continuous and batch weighing systems, contaminant-free bulk material storage, and mechanical and pneumatic conveying systems.
Eliminate the Doubt and Downtime of Force-fit, General Industry Equipment Sanitary processing operations are no place to settle for force-fit, general-industry bulk material handling equipment. In fact, such a compromise, and the inspection failures, retrofits, corrective fabrication and finishing, re-programming, and re-inspections that often result, have created a false perception of complexity and confusion when integrating bulk material handling equipment to sanitary process operations. Each NBE sanitary bulk material handling system is designed and built to be compliance-ready and to conform, from the ground up, to the unique and specific regulated processes and practices of each, individual
FDA, USDA, 3-A and cGMP-ready: Designed to Support Multiple Protocols.
application. NBE expertise in domestic and international standards across design categories, including: electrical and mechanical systems, hydraulics and pneumatics, and safety and controls is your assurance of
Bring clarity and confidence to bulk material handling equipment
best-practice sanitary machine and process design. The ability of NBE to
compliance and process acceptance procedures. The application-specific
start each design from an application compliance perspective, and then
design and construction of NBE sanitary bulk material handling systems
build equipment that is process-appropriate at start-up, ensures faster
enable processing and packaging operations to integrate deeper into
commissioning and standardization, improved operator safety, reduced
their production lines the efficiency advantages of sanitary bulk material
maintenance and training costs, and increased process contribution.
handling; without concern for contamination, time consuming sanitizing,
Look ahead to NBE. Look to Forward Thinking.
or complicated inspections. Whether direct, through consulting engineers, or in cooperation with multiple equipment suppliers, NBE applications and process engineering expertise will eliminate delays and accelerate acceptance, even across a variety of regulatory standards and guidelines. When there is no room for speculation or guesswork, leverage the advantages of NBE sanitary bulk material handling equipment and NBE, proactive regulatory compliance capabilities.
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PAUL MUELLER COMPANY Paul Mueller Company, headquartered in Springfield, Missouri, was established in 1940. For over 70 years, we have been building a reputation as an outstanding manufacturer of stainless steel tanks and industrial processing equipment that make the customer’s process smoother, faster, and more reliable. Mueller has evolved into a global process solution provider, offering manufactured equipment and components, integrated process systems, and expanded-scope construction. Our philosophy is simple: we are committed to meeting and exceeding our customers’ expectations of value by providing high quality equipment, excellent service, and complete process solutions. Mueller products are used in over 100 countries worldwide on dairy farms and in a wide variety of industrial applications, including food, dairy, and beverage processing; pharmaceutical, biotechnological, and chemical processing; water distillation; heat transfer; HVAC; heat recovery; process cooling; and thermal energy storage. Large field-erected vessels, equipment installation, retrofit and/or repair of process systems, process piping, and turnkey design and construction of complete processing plants are services provided by Mueller Field Operations, Inc., a wholly owned subsidiary. Transportation of the Companies’ products and backhauls of material and components are handled by another wholly owned subsidiary, Mueller Transportation, Inc. Mueller has the technical expertise, innovative engineering, and manufacturing resources to implement a process system specific to your needs. Let us provide your process solution!
Contact: Jim Hall and Mike Veatch P.O. Box 828 • Springfield, Missouri 65801-0828 Phone: 1-800-MUELLER • (417) 575-9000 • Fax: (417) 575-9669 http://www.muel.com • E-mail:
[email protected]
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OMEGA ENGINEERING, INC.
A Force in Domestic Manufacturing Because Omega Engineering offers over 100,000 products, many customers have the erroneous impression that the company is simply a catalog house, distributing products made by others. Actually, Omega is a major manufacturer in its own right, making over 80% of the products it offers, with this percentage continuously increasing. At a time when “outsourcing” seems to be the theme of many US manufacturers, Omega Engineering, headquartered in Stamford, Connecticut, remains a notable exception. The company has nearly 400,000 square feet of manufacturing space spread among 4 locations in nearly a dozen facilities located coast to coast, and, as new products are introduced, this domestic production space is increased. Here are some specific examples of current manufacturing operations at various Omega facilities. A customer using standard products may typically only require sales or application assistance, in the background is a huge pool of talented production line workers, product designers, software engineers, and automation experts. They are all ready and able to create and implement innovative custom solutions for difficult and unusual applications. During a period when American manufacturing continues to move offshore, Omega bucks this trend by continuously expanding domestic manufacturing space as new products are added. Make no mistake about it, Omega Engineering is a major manufacturer, and a good one. When you deal with them, you can be sure that you are dealing with a company that has their act together and has complete control over the quality, consistency, and reliability of their products.
Contact: OMEGA ENGINEERING, INC. One Omega Drive, Stamford, CT 06907 Tel: 203-359-1660 Fax: 203-359-7700
[email protected] www.omega.com
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Parker Balston Eliminate Contamination and Improve Food Safety Stainless Steel Filters for Wash Down Areas Parker Balston Stainless Steel Compressed Air Filters safeguard your operations from rust, pipescale, water, oil, and organisms usually found in compressed air. These filters will remove contaminants at a very high efficiency—up to 99.99% for 0.01 micron particles and droplets. Liquid releases from the filter cartridge to an automatic drain as rapidly as it enters the filter. This allows the filter to continue removing liquids for an unlimited time without loss of efficiency or flow capacity. The final stage of filtration removes all viable organisms with an efficiency rating of 99.9999+% at 0.01 micron. These filters will stand up to the harshest environments such as wash down areas. USDA/FSIS accepted for use in federally inspected meat and poultry plants. FDA compliant.
Steam Filter Permits Direct Steam Contact with Food Parker Balston Steam Filters remove 98+ or 0.1 micron particles and 100% 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. In full compliance with requirements of the US Food, Drug, and Cosmetic Act, Comply with USFDA, USDA, Health Protection Branch of Health and Welfare Canada, 3-A Accepted Practices.
Cabinet Dryers Eliminate Moisture Problems in Electrical Cabinets You demand a lot from your electrical cabinets. They are subject to nightly high pressure, hot washdowns, yet need to remain dry in a refrigerated environment. Over time, most cabinets develop moisture problems which result in premature component failure. A Parker Balston Cabinet Dryer will protect sensitive components from damage caused by water and high humidity by reducing cabinet humidity to less than 10% RH. Any water that infiltrates the cabinet evaporates quickly. Electrical components stay clean and dry resulting in prolonged life. A Cabinet Dryer will operate continuously and reliably without operator attention and eliminate lost production time. For additional information on Parker Balston product solutions for the food industry, please contact us at 800-343-4048 or 508-858-0505. www.balstonfilters.com
www.balstonfilters.com
1 800 343 4048
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Perfex Corporation
POWER Engineers, Inc.
Since 1924 PERFEX Corporation has become the nation’s principal manufacturer of unique and innovative cleaning tools designed for controlled environments. Our products are designed to be cost effective, easy to use, as well as heat, bacteria and chemical resistant. PERFEX Corporation designs and manufactures Cleanroom Mopping Systems, Microfiber and Sponge Mops, Brooms, Brushes and also a full line of sanitary handling products including Scoops, Shovels and Scrapers. We pride ourselves in delivering the highest level of quality and service to you. This passion keeps us constantly on the move, creating new products, improving others and aiming toward perfection.
POWER Project Management: Extending your Team POWER Engineers, Inc. (POWER) is a full-service, multidiscipline engineering firm with a strong commitment to delivering smooth, well-coordinated projects to food and beverage clients. Engineering services and project management are cornerstones of POWER’s business. We specialize in managing a portfolio of multiple, ongoing, interdependent project activities to achieve our clients’ overall business goals.
TruCLEAN Cleaning Systems • Isolate Contaminants to ensure the delivery of unadulterated cleaning and sanitizing agents • Components are constructed of high-grade stainless steel • Easy to maintain and guaranteed to deliver reliable results time after time • 100% compatible with gamma, ETO autoclave sterilization • Avoid risk of run-off contaminants, common with steam-sterilizers
POWER’s commitment to our clients is to: • Provide breadth of engineering disciplines • Apply hands-on project experience • Integrate service provider, client team, and key vendors/subcontractors • Apply safety, hygienic, and security design experience • Design sustainable solutions • Provide site management and coordinate commissioning, start-up, and verification • Drive value and innovation • Become an extension of your facility’s team
Brooms, Brushes & Squeegees • Color-Coded to avoid cross-contamination • Fibers Fused to brush block preventing premature fiber fallout • Lite-N-Tite Connection System extends brush life with unique selflocking design • Constructed entirely of Polypropylene, 100% recyclable and safe for the environment. • USDA and FDA Approved Please visit us online at PerfexOnline.com
Our solutions-driven project managers monitor project activities to ensure deliverables are provided as contracted and comply with the expectations of the project. Each project has a definitive work plan, formalized schedule, and agreed-upon budget that enhance the effectiveness of each member’s resources and helps to overcome coordination conflicts.
POWER’s project management is a carefully planned, organized program aimed at accomplishing established objectives. Rarely do our clients’ business objectives differ greatly from our own: we are both looking to optimize relationships, manage costs, drive revenues, and return value to shareholders. As a service provider, POWER strives to exceed our clients’ expectations. We maintain a cost structure that would be difficult for clients to obtain within their own organization. POWER provides multidiscipline engineering services from 30 worldwide locations to best support your project.
Contact: Perfex Corporation 32 Case Street Poland, NY 13431 Toll Free: 800-848-8483 Fax: 315-826-7471 Email:
[email protected]
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Contact: For more information, contact: POWER’s Food and Beverage Team Phone: 888-687-8811
[email protected] http://www.powereng.com/food Come and see us in September at Pack Expo (Booth C-2207) and in November at Process Expo (Booth 5212)!
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Reid Supply Company For All Your Industrial Products Reid Supply Company is a U.S. based global industrial products distribution company serving manufacturers, including those in the food industry. The company offers an impressive full-color 900 page industrial products catalog of their most popular products, which are also featured at ReidSupply.com. These products are distributed throughout the United States as well as to 57 other countries globally. Reid Supply serves multiple markets including Food Processing; Manufacturing; CAD and Engineering; Transportation Construction; Packaging; Oil, Gas and Alternative Energy; Government; Aerospace; and Medical.
Reiser Reiser supplies a complete line of equipment to help food processors produce all types of prepared food and deli salad products. Our range of equipment includes AMFEC mixers, Vemag portioners, Vemag cup fillers, and Vemag slice depositors for sandwich making. AMFEC Mixers AMFEC Mixers are ideal for gentle blending and mixing of even the most delicate products. A variety of agitator options are available, including their exclusive Faster Mix agitators (both paddles and ribbons), which eliminate the “logging” effect often seen in other Mixers. Vemag Portioners The Vemag Portioner is a food pump that provides the highest level of portioning accuracy, production efficiency and versatility, while consistently producing a high-quality product. The Vemag features a powerful, positive displacement double-screw pump that transports product extremely gently and without damage. A variety of innovative attachments make the Vemag a highly versatile machine.
ReidSupply.com is Reid’s powerful e-commerce website where Customers from all over the globe search for and buy industrial products with confidence. Our website offers FREE downloadable CAD drawings of over 90% of all parts featured in the catalog. Also in the site is the Reid SupplyLine, an online portal for news and information featuring Resource Guides; Tools You Can Use –a host of workplace calculators, posters, white papers and more. Today, Reid Supply Company is securely poised to serve now and well into the future.
Vemag Cup Fillers The Vemag Portioner with a Dripless Valve filling head attachment can be used to fill all types of containers – cups, tubs, pails and trays – accurately and gently without mess or container contamination. This is an economical solution to easily fill containers with exact-weight portions. Vemag Slice Depositors The Vemag Portioner with a Slice Depositor attachment is the perfect solution for producing all types of sandwiches quickly and easily. It deposits exact-weight portions of product mixtures such as tuna salad, chicken salad or condiment spreads directly onto sandwich bread. It portions cleanly and evenly, with no mess.
Ordering from Reid Supply is easy - call us, email us, fax us or place orders on ReidSupply.com Welcome to Reid Supply your industrial products distribution Company. Contact: Reid Supply Company 2265 Black Creek Road Muskegon, MI 49444-2684 Toll Free: (800) 253-0421 Local: (231) 777-3951 Fax: (231) 773-4485 E-mail:
[email protected] www.ReidSupply.com
Contact: 725 Dedham Street Canton, MA, 02021 Telephone: (781) 821-1290 Fax: (781) 821-1316
[email protected] www.reiser.com
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SIEMENS
SEW-EURODRIVE 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.
No matter how high your goals, Siemens can help move your business forward with our technological experience, local support and specific industry expertise concentrated on Food & Beverage in the US. The Siemens Food & Beverage Vertical Market Management (F&B VMM) team offers industry specific business solutions without silos or borders. We work to establish long term relationships in order to create references and develop strategic partnerships with industry-leading customers. F&B customers want to do business with partners who understand their current and future needs and have the ability to cross regional and functional boundaries to provide support for their key initiatives. Customers want partners who provide superior, creative solutions to difficult challenges. Siemens F&B VMM fulfills this objective.
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.
• Ability to enable F&B customer’s strategic initiatives such as sustainability, speed-to-market, quality, and flexibility.
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.
• Dedicated industry expertise in customer categories and segments
• Expert focus on solutions for strategic F&B industry challenges
• Global experience and world-wide support networks • Strategic management of complex relationships among customers, OEM supplier, solution partners, channel partners, and Siemens.
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 SEWEURODRIVE works every day to create innovative power transmission and motion control solutions that help the baking industry improve productivity, safety and profitability.
Contact: Chris Wood SEW-EURODRIVE PO Box 518 Lyman, SC 29365 P: 804-740-2269
[email protected] www.seweurodrive.com
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Contact: Siemens Industry Inc 1201 Sumneytown Pike Spring House, PA 19477 (423) 747-5850 www.usa.siemens.com/foodbev
[email protected]
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
SlipNOT® Metal Safety Flooring
Spraying Systems Co.
SlipNOT® non-slip stainless steel products transform slippery food processing environments into high traction work areas. SlipNOT® safety flooring products are used by food and beverage facilities to increase productivity and Non-slip stainless steel plate keeps workers worker safety while reducing safe at a meat processing facility. injury and liability. SlipNOT® products are very versatile and can be used as floor plates, grating, ladder rungs, stair treads, ladder rungs, crossovers, drains covers and platforms among other uses.
Spray Technology that Produces Results: • Increase quality • Improve food safety • Reduce waste • Minimize downtime Here are just a few ways to improve your operations with spray technology. For dozens more, call 1-800-95-SPRAY or visit www.spray.com.
SlipNOT® products are 100% grit free. The file hard surface is between 55-63 on the Rockwell “C” scale and has a bond strength of at least 4,000 psi. SlipNOT® non-slip products exceed all standards set by ADA and OSHA and are registered by NSF International. SlipNOT® safety flooring products provide a long lasting maintenance free alternative to slippery diamond plate and fiberglass SlipNOT flooring is available in products, while withstanding the caustic a variety of products to fit any enzyme environments that are found in many environment. ® food processing plants. SlipNOT anti slip flooring cleans easily by standard methods such as power washing and brushing. ®
SlipNOT® slip resistant products are available in stock sizes or can custom fabricated to detailed specifications. They can be sheared, welded, flame cut, torch cut, laser or water-jet cut, plasma cut, countersunk, and drilled for complete versatility both in the shop and field. SlipNOT® stainless steel slip resistant products create instant long lasting safety in every direction.
Contact: Sales SlipNOT® Metal Safety Flooring 2545 Beaufait St. Detroit, MI 48207 Ph. 313-923-0400, 800-SLIPNOT Fx. 313-923-4555 Website: www.slipnot.com Email:
[email protected] Women Owned: WBENC Certified Company
Slip resistant grating allows slippery substances to drain through while keeping employees on their feet.
Get Tanks and Vats Cleaner in Less Time Expanded line of TankJet® tank cleaning products ensures consistent, thorough cleaning of tanks up to 100’ (30 m) in diameter and reduces labor, water use, chemical use and wastewater disposal costs. Options include high-impact units for sticky residues, medium-impact rotating tank cleaners and a wide range of nozzles and spray balls for low-impact cleaning and rinsing. Compact Spray System Minimizes Overspray and Waste AutoJet® Model 1550 Modular Spray System provides automatic on/off control of electrically- and pneumatically-actuated spray nozzles. QC problems due to uneven application are eliminated, worker safety is improved as misting is minimized and the use of costly chemicals/ coatings is reduced through accurate spray placement. AccuCoat® Heated Spray Systems Ensure Even, Uniform Application of Viscous Coatings – Even Chocolate – with Minimal Waste AccuCoat 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 and manual systems including reduced coating use and less maintenance and downtime. AutoJet® Antimicrobial Spray Systems Help Meat and Poultry Processors Improve Food Safety These systems apply a predetermined volume of antimicrobial agent into packages or onto meat before sealing. Vacuum-sealing of the packages distributes the antimicrobial evenly around the product to ensure food safety. The system minimizes waste and reduces operating costs. 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]
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2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
SPX Flow Technology SPX Flow Technology SPX’s Flow Technology segment designs, manufactures and markets products used to process, blend, dry, meter, and transport fluids. Recognized for its leading brands and turnkey systems capability, the Flow Technology segment has global operations which serve the Food & Beverage, Power & Energy and Industrial markets. We offer a complete line of sanitary valves, pumps, scrape heat exchangers, homogenizers, mixers, dryers and evaporators for today’s modern processing facilities. It’s hard to find a more comprehensive portfolio of processing equipment anywhere else. Many of our designs incorporate patented features and our research and development efforts continue to produce ground-breaking technologies. Food and beverage manufacturing has never been more challenging. Margins are squeeze and food safety is paramount. Consumer demands for new products make formulation changes a regular occurrence. To meet these challenges head on, you need a partner with a deep understanding of process engineering and a broad portfolio of equipment. Explore the endless solutions that SPX Flow Technology has to offer. You’re sure to find answers that will improve plant performance, increase profitability and enhance the value of your brand.
Contact: SPX Flow Technology 611 Sugar Creek Road Delavan, WI 53115 Phone: 262-728-1900 or 800-252-5200 Fax: 262-728-4904 Email:
[email protected] www.spx.com
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Stonhard
Seamless, Hardworking Floors Keep Food & Beverage Environments Safe Stonhard has been providing long term flooring solutions for the food and beverage industry for 90 years. In addition to being sustainable, chemical, abrasion and impact resistant, our epoxy and urethane-based floors perform in extreme heat and cold, resisting both thermal shock and cycling. Found in bottling rooms, filling lines, kitchens, coolers, food preparation areas, mixing areas and process and packaging areas, Stonhard’s Stonclad and Stonshield systems are textured to prevent slips and falls and they stand up to oxidizing agents, organic acids and CIP chemicals. Our floors are also pitched to drains to prevent standing water from puddling and compromising sanitary regulations. And because Stonhard floors are seamless, there are no joints to trap dirt and bacteria, which keeps your food or beverage facility floors clean. This, along with Stonhard’s antimicrobial additive, Stonplus AM9, can play a valuable part in a food company’s intervention and food safety program. Stonhard floors have a low VOC content and we even offer floors that incorporate recycled and rapidly-renewable materials into their formulation and can help projects accumulate points as they pursue LEED certification. Every Stonhard system is backed by a single source warranty covering both products and installation and you receive comprehensive support from project managers, sales managers and Stonhard’s own installation teams from initial site evaluation to installation to completed job. Stonhard is proud to be the provider for Shearer’s Foods flooring needs. Congratulations on your Plant of the Year achievement!
Contact: 1000 East Park Avenue • Maple Shade • New Jersey • 08052 856-779-7500 • 800-257-7953 • Fax: 856-321-7525 E-mail:
[email protected] www.stonhard.com
2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Thermo Scientific 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 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 demanding, high-rate and high-accuracy systems. When you need to “see what’s inside the pipe,” the 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/littlethings, or call 1-800-227-8891.
Thermo Scientific product inspection helps customers
With thousands of systems installed around the
protect their brands by ensuring the quality and safety
world, we deliver reliable solutions through our
of their products. For more than 50 years, we’ve earned
application knowledge, equipment performance and
a reputation for delivering reliable solutions through our
unmatched customer care.
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
Contact: Thermo Scientific www.thermoscientific.com/littlethings 1-800-227-8891
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Triple/S Dynamics Triple/S Dynamics introduced the Slipstick® Horizontal Motion Conveyor to the food processing industry in 1982. Today, with thousands of conveyors installed around the world, the Slipstick Conveyor and other accessory components set the standard of performance and sanitation in food processing. Processors have many hot button issues including product breakage or degradation, sanitation and minimizing downtime. The Slipstick conveyor addresses all of these issues. The Slipstick is an oscillating mechanical conveyor driven with a slow-speed, horizontal differential motion and requires no fiberglass springs or base frame. The motion is a slow-advance and quick-return cycle that glides product along the length of the conveyor. This motion does not impact the product so breakage is greatly reduced or eliminated. The product is conveyed gently, intact retaining any added seasonings or coatings.
NEW E TRANSLICER® CUTTER DEFINES EFFICIENT, ENGINEERED EXCELLENCE Engineered to produce continuous precision slices with extensive detail given to key elements throughout the machine, the new E TranSlicer® Cutter joins the production-proven TranSlicer series in the Urschel line-up. “In 2010, we celebrated the company’s 100-year anniversary. On the heels of that, we are proud to announce the introduction of our latest TranSlicer. Building on a tradition of Urschel quality, this new machine demonstrates the company’s engineering-driven spirit which has been key to the company’s ongoing success all these years,” stated Tim O’Brien, vice president of sales at Urschel.
Food processors can rely on Triple/S Dynamics’ lineup of conveying equipment to solve their processing challenges.
The E TranSlicer uses the same 20” wheel and delivers the same types of cuts as its predecessor, the TranSlicer 2000 Cutter. The machine also accepts the same size infeed of 4” (102 mm) diameter firm products, more compressible products up to 6” (152 mm) diameter, and offers the same productionproven operating principle. In addition, the E TranSlicer provides a newly designed cutting wheel mount/holder assembly that simplifies cutting wheel changeovers. Hinged/sliding access panels offer full access to all key areas of the machine. To further ease washdowns, surfaces are sloped. Sanitary design ensures that all mechanical components are separated from the food zone. Electrical cables are slightly raised off of the machine frame to simplify washdowns and alleviate trapped food particulates. The E TranSlicer is available with across-the-line start or with a variable frequency drive.
Contact: Triple/S Dynamics, Inc. P.O. Box 151027 Dallas, TX 75315-1027 214.828.8600 800.527.2116 Fax: 214.828.8688 Email:
[email protected] www.sssdynamics.com
Contact: To learn more about the E TranSlicer, please contact: Urschel Laboratories, Inc. E-mail:
[email protected] Phone: (219) 464-4811 www.urschel.com PO Box 2200, 2503 Calumet Avenue Valparaiso, IN 46384-2200 U.S.A.
This horizontal motion also provides sanitary conveying as the gliding of the product along the seamless one-piece formed conveyor pan discourages build-up of materials on the surface. The continuous sliding action on the conveyor’s surface typically scours the pan clean so there’s less downtime. In addition to the Slipstick, the Triple/S Dynamics Tex-Flex Vibratory Conveyor, equipped with a screening section, can remove overs and/or fines that enter the product stream before cartoning.
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2011 | CORPORATE PROFILES SPECIAL ADVERTISING SECTION
Woodard & Curran
Woodard & Curran delivers sustainable designs and optimum performance to Food and Beverage industry clients. We have designed, permitted, and installed some of the most efficient manufacturing facilities in the world for beverage, dairy, protein, snack food, dressings and dips, and sauce manufacturers. The bundle of services Woodard & Curran offers is extensive. We provide the complete design, installation, startup, and environmental health and safety support needed for process lines and associated utility infrastructure, including: • Packaging equipment specification; • Bottle manufacturing design; • Manufacturing line layout design; • Water and wastewater; • Sustainability and product environmental footprinting; • Energy management; • Environmental compliance; • Compressed air; • Refrigeration and chilled water; and • Water resource management and hydrogeology. As an integrated science and engineering company, our clients have access to expertise a wide array of disciplines such as information management, automation (instrumentation and controls), training, site-civil permitting and design, and contract operations. We build successful partnerships and apply proven approaches to lean manufacturing. We deliver value by integrating best-in-class components that lower maintenance costs, decrease downtime, and increase efficiency. We measure success in line efficiency, waste minimization, streamlined handling, and plant flexibility with regard to both products and line balance. Woodard & Curran is a 600-person, integrated engineering, science, and operations company. Privately held and steadily growing, we serve public and private clients locally and nationwide.
Contact: Woodard & Curran Eric Carlson, PE Senior Vice President 41 Hutchins Drive Portland, ME 04102 800.426.4262
[email protected] www.woodardcurran.com
Zeppelin Systems USA, Inc. Zeppelin Systems is a world leader in the design, manufacture, and supply of automated material handling systems for powder and liquid ingredients. Our systems are installed in world class food and beverage companies around the globe. Zeppelin Systems provides engineered solutions customized to the specific needs of our clients. We emphasis the integration of dry and liquid material systems into the rest of the client’s manufacturing enterprise. Visit our web page www.zeppelin-usa.com to learn more about Zeppelin Systems. Competence and Tradition are an Advantage to our Customers Zeppelin Systems has been a source for complete solutions in process engineering and material handling for more than 120 years. Our areas of expertise include (but are not limited to) the following: Bulk ingredient unloading (railcar, truck, containers, bags) Bulk silos/tanks for dry & liquid ingredients Pneumatic conveying (dilute & dense phase; vacuum & pressure) Mechanical conveying (screws, trays, bucket elevators, belts) Liquids unloading, storage, transfer & metering systems Minor & micro ingredient systems Pneumatic blending Mechanical mixing Continuous mixing systems (Codos®) Continuous and batch fermentation systems Fat frying technology (i.e. Donut fryers) Sugar handling and grinding systems Process automation & controls System software (PRISMA®, recipe & production management system) Rockwell Automation Solution Provider Overall solutions from one source: Equipment and Components Process Technology Automation and Controls Project Management Service and Support
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www.foodengineeringmag.com | Food Engineering | June 2011
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June 2011 | Food Engineering | www.foodengineeringmag.com
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AD INDEX
Lubriplate Lubricants Co.
800-733-4755
12
32
Machine & Process Design Inc.
877-224-0653
4
314-733-2256
61
Marchant Schmidt, Inc.
920-921-4760
14-17
888-893-9277
96
Masosine Process Pumps
800-282-8823
98
800-528-7411
6
Material Transfer & Storage
800-836-7068
76
800-682-4594
5
MEPACO
920-356-9900
99
866-688-9611
89
Mitsubishi Electric
74
Mueller
888-828-4920
36
National Bulk Equipment
www.bel-ray/com
93
Netzsch Pumps North America LLC
BETE Fog Nozzles Inc.
413-772-0846
24
NTFE America
Big D Construction
800-748-4481
65
Omega Engineering Inc.
Breddo Likwifier
800-669-4092
IBC
Buhler Inc.
763-847-9900
Bunting Magnetics Co. Burns & McDonnell Case, Lowe & Hart Inc.
COMPANY
PHONE NUMBER
Air Blast, Inc.
626-576-0144
Alberici Constructors Allpax Arizona Instrument LLC Ashworth Atlas Copco Austin Company
PAGE
www.theaustin.com/foodgroup
Baldor Electric Company Bel-Ray
Chemetall
847-478-2100
95
800-MUELLER
43
www.nbe-inc.com/food 610-363-8010
44
507-786-9494
6
888-82-OMEGA
2
Pack Expo 2011
www.packexpo.com/food
23
97
Parker Balston
800-343-4048
800-835-2526
82
Perfex
800-848-8483
45
816-822-3831
51
Power Engineers
888-687-8811
57
801-399-5821
41
Process Expo
www.myprocessexpo.com
38
800-526-4473
67
Reid Supply Company
800-253-0421
33
718-821-1290
21
321-952-6600
26
Ross, Charles & Son Company
800-243-ROSS
11
Dorner
800-397-8664
84
Schenk Accurate
800-394-2941
20
800-768-7697
85
SEW Eurodrive
www.seweurodrive.com
59
Siemens
855-MY-CLARION
ElectriCities
28-29
Reiser
63, 81
Demaco
Clarion White Oils
www.usa.siemens.com/foodbev
86
SlipNOT Metal Safety Flooring
800-SLIPNOT
31
Specialty Equipment
713-467-1818
22
Eriez Magnetics
888-300-ERIEZ
18
Flexicon Coporation
888-353-9426
BC
859-448-2300
47
Fristam Pumps
800-841-5001
7
Gamajet
877-GAMAJET
44
SPX
www.spx.com
IFC
GEA Tuchenhagen North America
866-531-5629
34
Stonhard
800-257-7953
69
800-722-6622
27
Summit Industrial Products
800-749-5823
41
712-258-9300
75
Terlet USA
800-965-6065
10
Flottweg Separation Technology
GEA Westfalia Separator, Inc. Gleeson Constructors & Engineers LLC
Spraying Systems Co.
800-95-SPRAY
55, 71
Haskell Co.
904-791-4500
72-73
Thermo Scientific
800-227-8891
53, 78
Hinds-Bock Corporation
877-292-5715
30
Triple S Dynamics, Inc.
877-542-8010
9
www.hixson-inc.com
70
Urschel Laboratories, Inc.
219-464-4811
1
800-782-8850
83
Volkmann, Inc.
609-265-0101
39
Kagetec
612-435-7640
75
Wenger
Kason Corporation
973-467-8140
32
Woodward & Curran
www.ktron.com/info-paks
46
Zeppelin Systems
Hixson Inc. JAX
K-Tron Process Group
COMPANY
PHONE NUMBER
816-891-9272
40
www.woodwardcurran.com/fe
77
813-920-7434
42
PAGE
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.
134
35, 37
June 2011 | Food Engineering | www.foodengineeringmag.com
ENGINEERING R&D Kevin T. Higgins, Senior Editor
The insect management challenge
`
With chemical fumigants facing an uncertain future, a small group of scientists are investigating fresh approaches to insect management in stored grains. It’s no coincidence three of the 10 plagues of Egypt involved insects of one type or another. Ever since mankind learned to grow and harvest grains, people have waged a pitched battle with the insect world for a share of milled grains. A century ago, hydrogen cyanide was the fumigant of choice when attacking insect infestations in stored grain. Methyl bromide replaced it, but its days are numbered as a legal fumigant, and alternatives such as sulfuryl fluoride face an uncertain future. Indian meal moths, red flour beetles and other pests still will need to be controlled at flour mills, pasta and cereal plants and other food operations where milled grains are stored, of course. Fortunately, scientists at Kansas State University (KSU), Purdue University and USDA’s Agricultural Research Service Center for Grain and Animal Health Research are pursuing various options. Much of the work occurs in Manhattan, KS, home to KSU, in part because it is home to the Hal Ross Flour Mill, a 340,000-cu.-ft. pilot facility that provides a controlled environment where the efficacy of methyl bromide, sulfuryl fluoride, heat treatment and other commercial processes
` Bhadriraju Subramanyam, professor, International Grains Program, Kansas State University, Manhattan, KS.
can be evaluated for controlling insects in all life stages. Leading the effort since 1999 is KSU Professor Bhadriraju (Subi) Subramanyam. After earning an undergraduate degree from India’s Andhra Pradesh Agricultural University in 1981, Dr. Subramanyam received MS and PhD degrees in entomology at the University of Minnesota. At KSU, Dr. Subramanyam has established an internationally renowned stored-product entomology program, where integrated pest management programs for insects associated with stored grain are developed and evaluated.
Source: Kansas State University.
FE: Define the term, integrated pest management (IPM). Subramanyam: The whole point is managing pest
levels, not trying to get rid of pests entirely. A fundamental change occurred in the 1970s in California, when entomologists said, “Let’s not use the term ‘pest control’ anymore because it suggests elimination, which is impossible to accomplish.” The idea was to set a threshold level where management began. As long as insect populations are below that level, they concluded, humans and insects can peacefully coexist. IPM has been successfully applied to field crops, where threshold densities that trigger intervention are defined. But when it comes to stored grain, all we have are USDA standards that are too high to make pest management cost-effective. FE: What does the research say about the efficacy of heat treatment compared to chemical treatments?
Subramanyam: We conducted the first side-byside comparisons of methyl bromide, sulfuryl fluoride and heat treatment for managing eggs, larvae, pupae and adult red flour beetles in the Hal Ross Mill in May and August 2009 and May 2010. Three times more sulfuryl fluoride than methyl bromide was used. Temperatures during heat treatment were held between 50°-60°C (122°-140°F). All treatments were limited to 24 hours. All three achieved 90 to 100 percent kills of red flour beetles in bioassay boxes. Egg mortality was less than 100 percent with all three, though the differences were statistically insignificant. The only significant difference was in bioassay filled with flour 2cm deep (3/4 inch). Heat treatment mortality was 90 to 96 percent for certain life stages, significantly less than with the chemicals. This underscores the importance of sanitation for enhancing effectiveness: Flour is a poor conductor of heat, and adult insects will tunnel into the flour.
www.foodengineeringmag.com | Food Engineering | June 2011
135
ENGINEERING R&D
` Sara Savoldelli (left), visiting professor from University of Milan, and other researchers check bioassay boxes for kill rates after an insect treatment at the Hal Ross Flour Mill. Source: Kansas State University.
Air movement is important for heat distribution, and large fans were placed on each floor. Six air exchanges occurred each hour. We have very good data now on all three treatments. One of the things we’ve learned is that sulfuryl fluoride really needs to be combined with heat. If temperatures are below 80°F, you’re not going to kill the eggs. More gas has to be introduced or treatment time extended beyond 24 hours. The preferred option would be heating the facility to 85°F. FE: How does the cost of heat treatment compare? Subramanyam: One of my students
developed a side-by-side comparison of costs for the three treatment alternatives. Heat treatment costs include propane, equipment rental, transportation and per diem for four technicians. Overall, the cost of heat treatment was competitive. The average cost per cubic meter in the mill was $3.14 for heat, compared to $3.77 for sulfuryl fluoride. Methyl bromide at $1.76 was the least costly, but prices are going up as supplies grow shorter, and it is not a long-term option, in any case. FE: Have you modeled the cost of heat treatment? Subramanyam: We developed a cal-
culator around 2007, which we make available via license to commercial inter136
ests. It provides the heat transfer coefficient for an application, based on building specs such as exposed surfaces, materials of construction, heat loss and infiltration, outside temperatures, number and size of windows and doors and a variety of other attributes. Essentially, it lets you create a variety of scenarios and determine how many BTUs would be required for the applications, all while sitting at the computer. A rule of thumb is that it takes 7-10 BTUs per cubic foot per hour to conduct a heat treatment. But simply managing the program better can result in significant savings. At a cereal plant with 105 rooms, reducing heat treatment time to 24 hours from 34 hours saved $25,000. FE: Some of your recent work focuses on infrared radiation applied directly to foodstuffs, as part of disinfestation. What results have you achieved? Subramanyam: Flameless catalytic
infrared radiation is working great. Gasfired infrared radiation was evaluated several decades ago, but those emitters had an open flame, which posed an explosion hazard. Flameless technology using propane or natural gas does not suffer from the same drawbacks, and lab research indicates it is a promising tool for disinfestation, without having an adverse effect on grain quality. Infrared also kills pathogens and can be used to dry commodities. It will be cost competitive: We estimate treatment cost at 1¢-3¢ a bushel. In a feasibility study of wheat disinfestation with flameless IR heating, we achieved a 100 percent kill rate without adversely affecting the chemical and enduse properties of the wheat. Results are available on my website, www.ksre.ksu. edu/grsc_subi. And it’s green technology, with no VOCs and only carbon dioxide and water vapor as byproducts.
June 2011 | Food Engineering | www.foodengineeringmag.com
FE: If neither methyl bromide nor sulfuryl fluoride ultimately is available, will heat be the only option? Subramanyam: There is no magic
bullet for managing insects either in grain storage or processing plants. For processing facilities, a good sanitation program, coupled with good inbound and outbound inspection and occasional used of a fumigant or heat and fogging, can manage pests. One of the commercial projects we worked on resulted in development of a fermented bacterial insecticide that Dow Agrosciences markets as Spinosad. It is registered in many countries for use on crops, where it breaks down in a week when exposed to sunlight. In grain storage, it protects against infestation for two years. At 0.1ppm, 100 percent kill is achieved in the lesser grain borer, a problem insect with stored wheat. It is registered as a grain protectant in the US and has Codex approvals. Unfortunately, Japan has not accepted the tolerance, and until they do, commercial release will be delayed. FE: Have some promising treatments not panned out? Subramanyam: We studied ultrasound
extensively beginning in the late 1990s until 2006, but it only worked well on fleas and Indian meal moths. Coevolution occurs with bats and moths. The meal moth, for example, has a tympanic membrane and can perceive a bat’s signals, then make maneuvers to escape the bat. We built a random sound generator because the moths become habituated to a constant sound, and we found the sound stopped the moths from mating. But a piece of paper can stop the sound waves. FE: What’s the outlook for development of more alternatives for pest management in stored products? Subramanyam: There are only eight or
nine people doing this work in the United States, one of the smallest groups of entomologists working in a specific area, and the group is getting smaller each year. We need more students dedicated to postharvest protection. ❖
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