EXCLUSIVE REPORT: ENERGY AUDITS INDISPENSABLE FOR EFFICIENT PLANT OPERATIONS November 2011 |
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FEATURES COVER STORY
39
Sustainable Plant of the Year Efficiency was built into Frito-Lay’s Casa Grande plant a quarter-century ago, but the snack maker takes the facility’s energy- and water-conservation systems to a new level with near net zero.
51
Indispensable Energy Audits Energy audits and management can increase the bottom line, but to be effective, the job is never done.
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Flooring Commandment: Know Thy Installer Polymer science presents food and beverage manufacturers with many floor covering options, but performance often hinges on the expertise of the people installing them.
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Dry Processing Technology Tumble-turn-cut-fold mixing action yields 100% batch uniformity in less than three months.
20 DEPARTMENTS 8
Editor’s Note
10
Calendar of Events
13
Manufacturing News A brand new whey of packaging food
64
19
Food Packaging Processors add value to commodity cuts with cook-in bags.
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[email protected] Italy CORPORATE DIRECTORS Publishing John R. Schrei Corporate Strategy Rita M. Foumia Marketing Ariane Claire Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Directories Nikki Smith Human Resources Marlene J. Witthoft Information Technology Scott Krywko Conference & Events Scott Wolters Clear Seas Research Beth A. Surowiec
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November 2011 | Food Engineering | www.foodengineeringmag.com
See Food Master, p. 64
EDITOR’S NOTE
Making a difference in the battle of the bulge
I Joyce Fassl, Editor in Chief e-mail:
[email protected]
s it stress? Is it the economy? Is it modern lifestyles? Maybe it’s all of the above. Many Americans are just saying no to low-fat food and light beverages. And while many claim they want to drop pounds, most continue to eat high-calorie foods when dining out, bypassing the salad selections. With a third of Americans now considered obese, experts fear we may reach a 50 percent obesity rate in 20 years. According to an NPR report, even in health-conscious Colorado, obesity has risen from 20 to 21 percent. The trend also continues in traditionally fit nations like France where obesity is increasing. Some researchers believe the culprit is the change to modern lifestyles mimicking the American culture of larger portions and plentiful options. As cultures become more urbanized, young people are no longer interested in learning how to cook. As more women enter the workforce, they are no longer able to shop daily for fresh foods and take the time to prepare healthy meals for the family. Nutrition experts say it’s OK to indulge once in a while and that most people cannot maintain a restrictive diet for very long.
The challenge comes in managing cravings for tasty treats. I, for one, am happy to see calories listed on websites and fast food wrappers. In fact, I often consult a fast food website before my visit to the restaurant. I look for the wise options and check for whole grain bread offerings. I know I’d also think twice before ordering certain dishes in casual dining restaurants if calories were listed on their menus. It would definitely help manage my portion control, too. Last week, for example, I took advantage of a free frozen drink offered by a chain where I’m a loyalty card member. I checked the website for calories when I got home and promptly threw away the remaining half. It just wasn’t worth the calories. Some people think obesity can only be solved by the individual’s self control. I think our industry can make a huge difference in the battle of the bulge. Thank you to the food industry members who are making access to nutritional information easier. It’s helping at least one American make intelligent choices. ❖
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
November 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 Former Global Vice President, Safety and Environmental Sustainability Kraft Foods
David Haase Vice President of Operations WILD Flavors
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CALENDAR JANUARY 2012 15-18: 98th Annual NW Food Manufacturing & Packaging Expo and Conference; Oregon Convention Center, Portland, OR; Northwest Food Processors Association; www.nwfpa.org 22-25: IFPAC-2012 Annual Conference & Exhibition; Baltimore Marriott Waterfront, Baltimore, MD; International Foundation Process Analytical Chemistry; www.ifpacpat.org 24-26: International Poultry Expo; Georgia World Congress Center, Atlanta, GA; US Poultry & Egg Institute; www.poultryegginstitute.org
FEBRUARY 2012 6-9: ARC World Industry Forum; Renaissance Orlando at SeaWorld Marriott, Orlando, FL; ARC Advisory Group; www.arcweb.com 28-March 3: IPACK-IMA; Fiera Milano, Italy; Ipack-Ima spa; www.ipack-ima.com
MARCH 2012 14-17: FPSA Annual Conference; The Biltmore Hotel, Coral Gables, FL; Food Processing Suppliers Association; www.fpsa.org 17-19: SNAXPO; Phoenix Convention Center, Phoenix, AZ; Snack Food Association; www.snaxpo.com 27-30: Anuga FoodTec; Koelnmesse GmbH; www.koelnmesse.de
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`NEWS PLANT OPENINGS & EXPANSIONS Maple Leaf Foods celebrated the opening of its Hamilton, Ontario plant, which is Canada’s largest commercial bakery. The plant produces a variety of products for the Canadian market and represents a $100 million investment. The 385,000-sq.-ft. “Trillium” bakery features efficient design flow and best-in-class LEED technologies. Cargill will rebuild and expand its oilseed processing plant in West Fargo, ND. Construction is expected to start late fall 2011 with completion slated in time for the 2013 harvest. Project costs are expected to exceed $50 million. Toronto-based SunOpta Inc. is expanding its Modesto, CA non-dairy beverage processing facility to handle the production of aseptic, privatelabel, non-dairy beverages for big-box retailers. The expansion is expected to increase plant capacity by about 40 percent, and the company’s overall aseptic non-dairy and broth capacity by approximately 10 percent. The project is slated for completion in the third quarter of 2012. Algae Biosciences is expanding its omega-3 production facilities near Holbrook, AZ. The $5 million project is expected to be complete this year. The expansion will boost production of omega-3 fatty acid oils and high-protein algae meal, products primarily used in food additives and nutraceutical products. The facility is expected to produce about 5,900kg of whole algae powder a month by late 2012.
A brand new whey of packaging food
B
egun three years ago as an industry-driven, research and development project sponsored by the European Commission, W heyLayer is ending on a successful note. The purpose of the project is to develop a suitable whey proteinbased packaging replacement barrier film layer for non-recyclable, syntheticbased film products. The WheyLayer film, developed by Fraunhofer Institute for Process Engineering and Packaging (Fraunhofer IVV), had to provide both an oxygen barrier and water vapor barrier similar to its synthetic counterpart; it also had to be biodegradable. IRIS (Innovació i Recerca Industrial i Sostenible), a Spanish engineering group and partner in the project, is tasked with scaling up Fraunhofer IVV’s lab-based process to an industrial level and integrating the material in an industrial coating system. The WheyLayer material is laminated with a polymer substrate such as PET, OPP or PLA. In terms of recycling, the WheyLayer barrier coating can be dissolved completely without harming the substrate, making it easy for recyclers to reclaim the substrate. A barrier-layer film is important in food packaging to prevent the oxidation of fats, oils and other food components from off-flavors, change in color and loss of nutrients. Common synthetic films such as PE and PP are excellent moisture barriers, but must be coated or laminated with synthetic polymers including EVOH and PVDC copolymers to provide an oxygen barrier, according to the WheyLayer Project. The resulting polymeric structures are effective in minimizing oxygen permeation, water vapor
` This machine is part of the coating application in the lacquering/laminating plant used to process WheyLayer films. Inset shows sample foods packaged in WheyLayer material. Source: Fraunhofer IVV.
and odors, but are not very reusable for recycling because of the difficulty in separating the layers. Recent research found that whey, the milk protein byproduct of cheese production, acts as a good moisture barrier with acceptable mechanical integrity. In addition, the use of the whey-layer coating on plastic films improves the recyclability and reuse of the plastic layer because the whey protein can easily be removed chemically or by using enzymes. IRIS exhibited results from the ongoing project at Interpack in May. The first demonstration session for the WheyLayer project was held at IRIS on Sep-
www.foodengineeringmag.com | Food Engineering | November 2011
13
MANUFACTURING
`NEWS tember 22. Various packaging items and samples based on WheyLayer were exhibited as well as the recycling process at lab scale. The WheyLayer project prototype machine built at IRIS was demonstrated to coat PET films at semiindustrial speed.
14
In addition, a W heyLayer demonstration was held in October at the TUBA(supplier of packaging materials) facility in Ljubljana, Slovenia. Fraunhofer IVV will show its new packaging film at the November 2011 Munich “Sustainability in
November 2011 | Food Engineering | www.foodengineeringmag.com
Packaging: Process and Materials” conference. According to WheyLayer’s Executive Summary 2.1, research activities led by Frauhofer IVV were to develop and select WheyLayer formulations best suited for achieving barrier property specifications of less than 20 cm3/ m2 d bar for oxygen (23°C, 50 percent RH) and less than 50g/m3 d for water vapor permeation (23°C, 85 to 0 percent RH) for protein on polymer film substrates like PET, OPP or PLA. Since whey proteins as raw materials for coatings show a wide spectrum of properties, extensive chemical, physical and functional characteristics tests were performed on carefully selected, commercially available whey protein concentrates (WPCs) and isolates (WPIs). Processing properties of the whey protein products were, in general, improved with increasing protein pureness and maintained protein nativity, according to the summary. WPIs from both sweet whey and sour whey were produced in a pilot scale using a combined ultra- and micro-filtration process. The aim was to produce products with better adapted properties and to produce not-commercially available WPI from sour whey. The adapted process was suitable to process both types of whey and to produce WPIs with protein contents of 95.9 percent d.m. for sweet whey and 92.9 percent d.m. for sour whey respectively. Missing protein properties for an excellent WheyLayer coating were introduced by elaborating formulations with additives like plasticizers (glycerol, sorbitol, PEG [polyethylene glycol] and PG). After further research and testing for rheological behavior, film-forming properties and water resistance, two formulations achieved the required specified properties, and were selected as first-coating materials on polymer substrates like PET, OPP and PLA. For more information, visit www. wheylayer.eu.
REGULATORY WATCH Milk producers seek right to reduce output when prices are low
“By creating a level playing field, the FTAs with South Korea, Panama and Colombia will increase our competitiveness in these countries and help the food, beverage and CPG industry innovate, expand and create new jobs,” says Bailey.
“Our competitors have negotiated their own trade agreements with Colombia, Panama and South Korea. The European Union’s trade agreement with South Korea went into effect July 1, and a trade agreement between Colombia and Canada became effective August 15,” adds Bailey.
Milk producers and dairy processors are clearly at odds over major new dairy legislation now in Congress. The Dairy Security Act of 2011 is backed by the National Milk Producers Federation (NMPF), which said the legislation is modeled on its proposals and would improve the farmlevel safety net for producers. Under the legislation, the Dairy Market Stabilization Program would reduce milk output at times when milk prices are low. Connie Tipton, CEO of the International Dairy Foods Association (IDFA), calls the bill’s pricing provisions unacceptable. “IDFA opposes milk pricing regulations that increase the already significant regulatory burden on processors, put pressure on declining milk sales and increase costs for consumers, as well as many government nutrition and feeding programs that are already stretched to serve Americans who are struggling to feed their families,” Tipton states. She says the legislation would give dairy cooperatives “the power to veto rules” developed by the Secretary of Agriculture. The bill was introduced in the House in late September.
Trade agreements expand US surplus The Grocery Manufacturers Association (GMA) praised President Obama’s signing of free trade agreements with Colombia, Panama and South Korea. The agreements are critically important to increasing exports of US food and consumer products. “We applaud President Obama for signing free trade agreements [FTAs] with Colombia, Panama and South Korea,” says Pamela G. Bailey, GMA president and CEO. “The food, beverage and consumer packaged goods [CPG] industry exports $50 billion worth of goods to 215 countries around the globe, generating a $10 billion trade surplus. www.foodengineeringmag.com | Food Engineering | November 2011
15
MANUFACTURING
`NEWS INDUSTRY & PEOPLE Northwest Food Processors Education & Research Institute and the Hitachi Foundation are jointly offering the 2012 Food Processing Workforce Pioneer Awards for food companies with
facilities in Idaho, Oregon and Washington. This award will recognize employers whose successful businesses are built on developing opportunities for economic advancement for their lower-income employees
in production, packaging, sanitation and other non-managerial positions. McCormick & Company, Inc. has created the new position of chief science officer on its leadership team. Dr. Hamed Faridi, a food scientist, researcher FARIDI and 14-year veteran of McCormick, assumes this role. PepsiCo announced that Eric J. Foss, chief executive officer of the Pepsi Beverages Company (PBC), will retire in December 2011. PepsiCo also named Albert P. Carey as its new CEO of PepsiCo Americas Beverages. Carey previously served as president and CEO of Frito-Lay North America. James P. Young was named logistics manager for YOUNG Wixon, a manufacturer of seasonings, flavors, ingredients and consumer products. Joe Stout, former global director of product protection, sanitation & hygienic design at Kraft, will serve as a food safety consultant to the Food Safety Task Force of the Food Processing Suppliers Association. Kasey Moctezuma of Quality Assurance International, an organic certification organization, was appointed to serve on USDA’s Agricultural Technical Advisory Committee for Trade in Processed Foods. Baltimore Aircoil Company promoted Michael Swiderski to the position of
16
November 2011 | Food Engineering | www.foodengineeringmag.com
president. He succeeds Steve Duerwachter, who announced his retirement.
equipment for the controlled application of liquid and dry ingredients.
Siemens appointed Helmuth Ludwig as chief executive officer of the company’s industry sector in North America.
3M Food Safety introduced a new test called the Aerobic Procedure for
Lactic Acid Bacteria. This procedure enumerates lactic acid bacteria in food and environmental samples, and is the result of a long-term relationship with Kraft Foods.
Eldon Roth, Beef Products Inc. inventor and innovator, will be inducted into the Meat Industry Hall of Fame. LUDWIG
SABMiller will purchase Australian brewer Foster’s for approximately $10.2 billion. Powerit Solutions announced that Kevin Klustner joined the company as CEO. Sealed Air Corporation completed the acquisiKLUSTNER tion of Diversey Holdings, Inc., a solutions provider to the global cleaning and sanitation market. The board of governors of Material Handling Industry appointed George W. Prest to the position of chief executive officer of Material Handling Industry of America. Prest succeeds John Nofsinger who is retiring at year’s end. Nofsinger has more than 45 years of experience in the material handling and logistics industry. ONEsource Facility Solutions named Ed Wright as its president and CEO. Pilgrim Software, Inc. appointed Thierry Durand as its chief executive officer and a director of the executive board. Heat and Control, Inc. purchased Spray Dynamics, Ltd., a provider of
www.foodengineeringmag.com | Food Engineering | November 2011
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FOOD PACKAGING Kevin T. Higgins, Senior Editor
It’s in the bag
`
A canola-based plastic resin is the latest wrinkle in a larger effort to get protein processors to add value to commodity cuts with cook-in bags.
C
ook-in bags for turkeys have been around since the 1970s, and hermetically sealed vacuum bags for protein products have a decade’s worth of applications under their belts. But change comes slowly in food processing, and adoption of these bags to add value to commodity cuts is just beginning to heat up. Following a few false starts, Sealed Air’s Cryovac division rolled out Oven Ease bags in recent years, targeting foodservice operations with a package that retains meats’ juices and prevents cross-contamination of precooked items for school lunches (see “Packaging materials innovations,” Food Engineering, January 2010). Cryovac was following the lead of Schuylkill Haven, PA-based M&Q Packaging Corp., a film converter that has aggressively promoted the cook-in bag as a way for further processors and packers to generate more profitable sales. M&Q’s
` Raw chicken isn’t visually appealing, even when it’s fully seasoned, but when placed in a cook-in bag, it is safer and more convenient for the cook and more profitable for the processor. Source: M&Q Packaging.
latest innovation is an outer-ply resin fabricated from canola oil that has been modified to perform like a polyester. The MQ120 Oven Bag qualifies for a No. 1 resin recycling code, a distinction M&Q hopes will increase the bags’ sustainability credentials. Replacing the polyolefin and nylon in conventional oven bags may result in a greener footprint, but MQ120 is a minor improvement in a packaging idea with significant potential. For the at-home cook, ovenable bags can reduce preparation time to a third, while delivering a meal with the flavor Grandma derived from a pressure cooker. For a restaurateur, cook-in bags slash preparation time and safeguard meats from human contamination, while retaining juices for gravies and other stock-pot uses. For the food processor, a bag can turn raw meat or poultry into a seasoned, ready-to-cook product that commands a higher price while adding only a nominal cost. “The traditionalists keep pushing back,” allows Curt Rubinstein, M&Q’s sales & marketing manager, “but the marketing groups get excited about this because they can sell a product that sounds like it’s fully cooked but doesn’t have any of the costs involved.” As an example, he cites pork ribs: Absent precooking or a cook-in bag, ribs are “just bones [hog processors] have to get rid of.” By giving people a way to prepare juicy ribs in about an hour, pork producers turn ribs into value-added meats. Perdue has steadily expanded its Oven Ready line to five offerings, and Jennie-O and other processors are marketing meats and poultry in cook-in bags. Rubinstein points out his bags tolerate a higher level of cook temperatures for faster preparation time than bags using nylon, and a larger cooking dome results in better flavor. “The only real downside is that the sealing of the bag is a challenge,” he concedes. Whereas nylon bags might tolerate a sealing temperature variance of plus or minus 20 degrees, his bags have a narrower window. But if plant engineers are up to the challenge of tighter sealing tolerances, processors and their customers stand to benefit. ❖ For more information: Curt Rubinstein, M&Q Packaging Corp., 864-261-8800,
[email protected]
www.foodengineeringmag.com | Food Engineering | November 2011
19
FOOD PACKAGING
What goes with a donut?
J
ust as gas stations morphed into convenience stores, donut shops evolved from coffee shops. Mindful of its roots, K r i s p y K r e m e D o u g h n u t Co r p. i s updating its java line, including an overhaul of the to-go bean bag. The f resh-lock bags feature new graphics depicting different coffee-drinking occasions, including the office, at home and—where else?—a donut shop. The overhaul also represents a scaling back, according to Lafeea Watson, media manager in Krispy Kreme’s WinstonSalem, NC headquarters. Instead of five varieties, the chain now packages Signature House, Signature Dark Roast and Signature House Decaf in 12-oz. bags. “ We found there wasn’t a significant difference between the [former] bold and rich roasts,” she explains. “Only about 20 stores in the country” sell the coffee bags, says Watson, not including Krispy Kreme’s 650 locations
` The donut shop experience can be replicated at home with Krispy Kreme’s three new coffee blends. Source: Krispy Kreme Doughnut Corp.
worldwide. And while competitors such as Dunkin’ Donuts have muscled their way onto grocers’ shelves, the number of brands in the retail coffee channel has surpassed critical mass, and Krispy Kreme is focusing on the Internet and its own stores for coffee sales. ❖
7JTJUVTBU1SPDFTT&YQPt#PPUIt/PWFNCFS t$IJDBHP *-
donaldson.com
See Food Master, p. 52
November 2011 | Food Engineering | www.foodengineeringmag.com
ageme an
9001:2008
© 2011 Donaldson Company, Inc. Minneapolis, MN. All rights reserved.
20
Registered:
ality M Qu
Tel 800-543-3634 Fax 952.885.4791 processfi
[email protected]
System nt
Donaldson Company, Inc. Compressed Air and Process Filtration PO Box 1299 Minneapolis, MN 55440-1299 U.S.A.
ISO
Standard No. 10-04*
* PF-EG & PG-EG single filter element housings meet 3-A Sanitary Standards.
Wow… nice package!
We’ve got the perfect package to fight contamination in washdown applications: 304 stainless steel helical (bevel or inline) gear reducer: • 95.5%–97% efficiency • C-face or IEC input • PTFE seals on output shaft • smooth body minimizes particle and bacteria collection • highly resistant to most acids, alkalis and corrosion 304 stainless steel C-face motor: • encapsulated stator and conduit box • antibacterial treatment • premium 6200 series stainless steel bearings • double-lip FKM seals Movitrac LTE-B inverter: • IP66/NEMA 4X enclosure • SBus (CAN based) communicates with PLC • single or three-phase input
seweurodrive.com
TECHNOLOGY S O U R C E B O O K
HIGH-SPEED DISPERSERS
AIR KNIVES Powered by energy-efficient regenerative blowers, Spraying Systems WindJet air knife drying packages eliminate the need for compressed air in a range of operations including debris and dust blow-off, removal of excess water and moving products. Available in lengths from 6 to 36 in. and with .040- and .060-in. air slot sizes, the knives feature a 1/8-in. leading edge along their length to direct a controlled air stream. Regenerative blower assemblies are available from 5.5 to 30hp. The air knife drying packages include a pressure relief valve, pressure gauge, air inlet filter, filter monitoring gauge, vibration dampener, fittings and mounting adapter. Spraying Systems Co.; 630-665-5000; www.spray com
SHRINK SEALER Variable in speed, the PDC 90-2 shrink sealer has a dual-head capability and can seal over 400 containers/min. or run as slowly as 100 cpm per head to
synchronize with production. The sealer applies single- and multi-layer PVC, PETG, PLA and OPS bands in gauges as thin as 40 microns. Compatible diameters range from .375 to 3.0 in.; height ranges are .625 to 8 in. A changeover feature allows a second reel of film to be staged while operation continues at normal speed. When the current reel is spent, an end-of-reel sensor automatically shuttles the second head into position and engages the new reel. Standard features include a stainless steel frame, NEMA 4 enclosures, AllenBradley touch screen and PLC, static eliminator and blade assembly without spinning knives. PDC International; 203-853-1516; www.pdc-corp.com
Suitable for most straightforward powder wet-out applications up to 50,000cP, Ross high-speed dispersers come with heavy-duty precision bearings and drive assembly, high-quality stainless steel wetted parts and shaft guard, and an air/ oil hydraulic lift with controls. Features include a 10-gauge thick, laser-cut stainless steel saw-tooth blade; adjustable can lock system; and a TEFC or explosionproof inverter-duty motor. Optional blade styles, ultra-high molecular-weight polyethylene blades, a variable frequency drive and an explosion-proof operator station are available. The dispersers come in sizes from standard laboratory models for batches as small as 1 gallon to production units for vessels up to 500 gallons. Charles Ross & Son Company; 800243-ROSS; www.mixers.com
ROTARY CHAMBER MACHINE The Rollstock RC-300 rotary chamber machine features a 304L stainless steel modular frame with the ability to accept a range of chamber configurations, sealing profiles and sealing widths up to 24-in. long. The unit’s constant temperature sealing system allows sealing through thick bags, contaminants and excessive folds and wrinkles. Rollstock, Inc.; 888-314-2152; www. rollstock.com
www.foodengineeringmag.com | Food Engineering | November 2011
23
TECHNOLOGY S O U R C E B O O K
clear. safe. solutions. Clarion provides the most highly refined white oils available to help 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 Clarion Food Grade FR Fluid Clarion Food Grade White Mineral Oils Clarion Food Machinery Grease, No. 2 Clarion Food Machinery A/W Oils Clarion Food Machinery Gear Oils Clarion Food Machinery HT EP Greases Clarion PM Hi-Temp Food Machinery 100 Greases Clarion Chain and Trolley Lube COMMITTED Our technical field support team is able to optimize your operation by creating custom solutions.
PLC-CONTROLLED PALLETIZER Using a common programmable logic controller platform, the Intelligrated Alvey PLC-controlled robotic palletizer is an alternative to the traditional proprietary robot. The PLC-based control system enables users to deploy Alvey robotic palletizing solutions while maintaining their standard control platform and provides a compact footprint by eliminating the need for additional control cabinets for each robotic application. Intelligrated; www.intelligrated.com
RELIABLE Clarion Food Grade Lubricants are NSF H-1 registered and Kosher certified.
field calibration, the 3-in. Type 1084 pocket test gauge covers ranges to 1,000psi with 0.5%FS accuracy. Ashcroft Inc.; 800-328-8258; www.ashcroft.com
To learn how Clarion can refine your operation, call 855-MY-CLARION or visit clarionlubricants.com.
MOLDED-FIBER BOTTLES
TEST GAUGES Ashcroft Type 1082 and Type 1084 test gauges test and certify pressure monitoring devices. Available in 4 1/2-, 6and 8 1/2 in.-diameters, the Type 1082 gauge provides +/-0.25%FS accuracy in ranges from vacuum through 10,000psi; an external zero adjuster, temperature compensation and Monel wetted parts ensure precision and media compatibility. Engineered for
Ecologic Brands eco.bottle molded-fiber bottles are available in 32-, 50- and 64-oz. sizes to house liquids or dry food-grade products. The bottles are comprised of a sturdy molded fiber shell, made from recycled cardboard and newspapers, and a thin interior #4 low-density polyethylene plastic, BPA-free pouch and spout. The outer shells tightly nest and can be transported flat; they can be recycled or composted. The plastic pouch is recyclable with plastic grocery bags at retailer drop-off bins. Ecologic Brands; www.ecologicbrands.com
See Food Master, p. IFC 13, 36-41 November 2011 | Food Engineering | www.foodengineeringmag.com
IMAGINE A WORLD WITHOUT CONTAMINATION OR DOWNTIME.
FOOD GRADE
We know how hard you work to meet demand and stay competitive. But no matter how meticulously you service your equipment or how much skill your workforce acquires, accidents happen. Something as simple as a ruptured hose can lead to lost profit, missed deadlines and even e damaged reputations. That’s why we created Clarion Food Grade Lubricants. This full line ne o off NSF H-1 regist registered food grade products including oils, greases and fluids has been sp pecifically formulated to iinhibit nhibit oxidation and provide anti-wear properties to safeguarrd your operation and givee your bottom line the security it des deserves. ser
clear. safe. solutions.
TECHNOLOGY S O U R C E B O O K
INNOVATIVE STEAM SOLUTIONS Worldwide Boiler Energy Savings: $134-Million! Since 1930, Clayton Industries has taken the lead in steam generating equipment design, manufacturing and service. With an ever-growing diverse and unique line of steam generators, they’re used in a broad range of major industries worldwide.
Here’s what makes Clayton your best choice:
PROCESS CONTROL With an EMM interface module, the Moore NET Concentrator System process control and distributed I/O network comes standard with an Ethernet (MODBUS/TCP) port and dual, independent MODBUS RTU (RS-485) ports. The system can be used as either a single or dual MODBUS master, allowing it to provide simultaneous Ethernet and dual MODBUS RTU master/slave communications. Designed to work in demanding industrial applications and settings, it has an ambient temperature range of -40°F to 185°F and a 20-bit input/18-bit output resolution. Users can view, select and set operating parameters for both Ethernet and dual MODBUS parameters through the Internet Explorer Web browser or free Intelligent PC configuration software. Moore Industries-International, Inc.; 818-894-7111; www.miinet.com
• High Productivity – Clayton Steam Generators are in 18 sizes that range from 10 to 1,000 bhp and with design pressures from 15 to 3,000 psi. They start up and stop quickly, assuring a consistent supply of dry clean steam with no wasted energy.
for use on circuits from 0-15 to 0-600 VDC, they provide industry-standard 4-20mA loop-powered output, making them compatible with existing controllers, data loggers and SCADA equipment. The input and output circuitry is fully isolated for operational safety. NK Technologies; 800-959-4014; www.nktechnologies.com
• Space Efficiency – Clayton’s exclusive vertical design allows for a space saving very small footprint. • Safety – All Clayton Steam Generators, including its signature Sigma-FireTM series, are 100 percent explosion-proof! • Energy Efficiency – Being more efficient than any other boiler designs, Clayton Steam Systems consistently provides significant energy savings. • Clayton Steam Boilers are built to last! Our expert team of engineers and technicians provide 24/7 service and maintenance assistance. Please contact us or visit our website to learn more.
World Headquarters 17477 Hurley Street City of Industry, CA 91744-5106 800.423.4585 tel • 626.435.0180 fax email:
[email protected] www.claytonindustries.com
COMPRESSED AIR FILTER
VOLTAGE TRANSDUCERS Packaged in a 35mm-wide DIN-rail enclosure, NKT VTD Series high-performance voltage transducers sense voltage in an array of DC-powered installations, including industrial motors, battery chargers, photovoltaic arrays and wind generators. The transducers help avoid motor overheating by detecting below normal voltage conditions and voltage conditions that can stress or damage starter components. Suitable
Engineered for point-of-use filtration of compressed air in a variety of applications, the Donaldson DF-Three filter features 3 stages of purification: aerosol coalescing, hydrocarbon vapor adsorption and particulate removal; it can also be used as a compact treatment unit for small compressors to generate pure compressed air. Validated according to ISO 12500-1, the filter achieves an overall residual oil content of <0.003mg/m³ and Class 1 compressed air quality according to ISO8573-1:2010. Donaldson Company; 800-543-3634; www.donaldson.com
November 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
Providing the Full Spectrum in Separation Technology
BENCHTOP LAB MIXER
FLOW COMPUTER Conforming to the temperature compensation calculations of SAE ARP 4990, the COX Flow Measurement ExactComp EC80 flow computer accepts 4- and 10-ohm pick-offs, and includes dualrotor frequency and RTD temperature sensor inputs for either single- or dualrotor turbine flow meters. It tracks all variables to compensate for viscosity and rotor blade variations by using selectable blade averaging coupled with a rolling average output. Enhanced Digital Signal Processing technology enables signal characterization using a 32-bit floating point processor at 150 MHz having a process latency of 100 μS, while outputting linearized data in engineering units. The computer is available with packaging for remote, direct or embedded mounting. COX Flow Measurement; www.coxflow.com
No matter the task, our full line of equipment is up to the job. Besides offering stand-alone separators, clarifiers and decanters in multiple sizes and capacities, GEA Westfalia Separator can work with you to solve complex food processing challenges. In many cases, we can even recommend a complete processing solution that will efficiently meet your needs. To learn more about the spectrum of separation technology we can provide, contact Philip Cunningham at 510-432-4732 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
1500T
Handling up to 15 liters, the Admix BenchMix Model OPLB-400 high-shear benchtop lab mixer provides versatility with multiple high-shear heads, lowspeed impellers and props. It is available with 3hp at 12,000rpm, a low-batch level adapter and adjustable beaker clamp. Once satisfactory results are obtained with the mixer, users can accurately scale up to production volumes. Admix, Inc.; 800-466-2369; www.admix.com
TECHNOLOGY S O U R C E B O O K
PRESSURE/LEAK DETECTOR PALLETIZER
Used to inspect PET and HDPE containers for low pressure caused by misplaced caps, stress cracks, pinholes and other defects, the filtec pressure/leak detector has a beltless system that eliminates the squeezing of bottles to detect improper pressure. Precisely positioned guide rails firmly support each bottle while it is inspected by an intelligent sensor utilizing a proprietary algorithm. When the pressure is outside acceptable limits, a defect is indicated, and the bottle is rejected from the line. filtec; www.filtec.com
Reducing corrugated consumption, the A-B-C Model 72A palletizer automatically palletizes small packages and builds endaisle display pallets. A custom infeed orients, collates and feeds product to the stainless steel staging table. A sweep-bar guides the layer to the pallet stack; the 4-side squaring device tightens and squares each layer. A-B-C Packaging Machine Corporation; 800-237-5975; www.abcpackaging.com
We’ve got sssssteam heat... Ready to shift your food production to a more favorable continuous process? The new Wenger Thermal Twin Screw Extruder allows previously unheard of high levels of thermal energy for a more gentle cooking process compared to high-shear cook. Products high in corn or rice content can be processed without the stickiness typically encountered in conventional extrusion systems. The new Thermal Twin design allows ingredients to be fully cooked without damage to the starch or protein matrix. The unique screw profile, combined with an innovative extruder barrel design permits up to four times steam injection for unprecedented savings in both energy costs and equipment wear. Get details now on the revolutionary Thermal Twin Screw Extruder Series, with flexibility to meet your specific needs, at www.wenger.com. At Wenger, we innovate to solve customer challenges.
And then we do it again. Inventing the new original since 1935. SABETHA, KANSAS USA
BELGIUM
USA
785-284-2133
TAIWAN
BRASIL
See Food Master, p. 132
28
November 2011 | Food Engineering | www.foodengineeringmag.com
[email protected] CHINA
TURKEY
TECHNOLOGY S O U R C E B O O K
COMPONENT MATERIAL
TABLETOP DEPOSITORS Gently handling all batters, Hinds-Bock tabletop depositors maintain the integrity of quality products. They can handle a variety of pan configurations such as muffin, cupcake, sheet cake and rounds with a simple changeover. The depositors are available with up to 7 pistons. Hinds-Bock Corporation; 877-292-5715; www.hinds-bock.com
Developed for the food industry, Ensinger TECAFORM FG Blue material makes equipment components more visible to optical inspection systems since blue is the only color that does not widely occur naturally in the food chain. Manufactured from FDA-, USDA- and 3A Dairy-compliant resin, the component material is resistant to hot water and typical cleaning chemicals. Exhibiting low internal stress and good bearing and wear properties, it can be used for bushings, rollers, wear strips or color coding similar parts made for different lines or pieces of equipment. Ensinger Inc.; 800-243-3221; www.ensinger-inc.com
* TankJet® 360 Tank Cleaner
Downtime for tank cleaning can significantly impact production levels. Our recently expanded tank cleaning product line includes many solutions to clean your tanks in less time – and return them to service more quickly without compromising cleaning quality. Whether your tanks are 2 ft. or 100 ft. (0.6 or 30 m) in dia.; require rinsing or high-impact cleaning, our local sales engineers will help you select the right tank cleaner. The results: UÊVÀi>Ãi`Ê«À`ÕVÌÊÌi UÊ«ÀÛi`ÊVi>}ÊVÃÃÌiVÞÊ
i>ÀÊÀiÊ>ÌÊÌ>iÌ°V
TankJet 65 Tank Cleaner
TankJet AA190D Tank Cleaner
TankJet 18250A Tank Cleaning Nozzle
* Reductions in cleaning time will vary based on current cleaning methods and the tank cleaner installed. Multi-hour operations can often be reduced to 60 minutes or less.
See Food Master, p. 110-111 www.foodengineeringmag.com | Food Engineering | November 2011
29
TECHNOLOGY S O U R C E B O O K
CLOSE-COUPLED PUMP BLOWDOWN CONTROL SYSTEM Providing continuous control of the surface blowdown rate for commercial and industrial boilers, the ECD automated Model 61 boiler blowdown control system reduces scaling and corrosion. The system calculates total dissolved solids levels by measuring conductivity in the boiler water. A CS10 conductivity sensor with a standard range of 0 to10,000 μS or optional ranges of 0 to 1,000 μS or 0 to 100 μS makes the conductivity measurement. Electro-Chemical Devices; 800-729-1333; www.ecdi.com
The Moyno 1000 close-coupled positive displacement pump can be used for shear-sensitive chemical feeds, adhesives, lime, polymer metering, slurries and viscous crude oil transfer applications. Allowing mechanical seal access, the 2-piece drive shaft eliminates the need for complete pump disassembly when the seal is serviced. The pin-type universal joint is sealed and lubricated. Additional features include a low-shear pumping action, non-pulsating flow, pressure capabilities to 350psi and flow rates from 0.38 to 320gpm. Moyno, Inc.; 877-4UMOYNO; www.moyno
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.
If it’s in the retort room, we can do it.
Go to www.AllpaxRetorts.com or call 1-888-893-9277 for more information
30
November 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
ELECTRIC LIFT TRUCKS Featuring 4 models ranging from 4,000- to 6,000-lb. capacities, Nissan Platinum QX Series 80-volt electric lift trucks use 100% AC power. They have a tight turning radius, low center of gravity and regenerative braking system. The trucks come standard with programmable PIN access to help prevent unauthorized use, an automatic mast-lock system that prevents mast or fork movement when an operator is not in the seat and controlled rollback. Nissan Forklift Corporation; 815-568-0061; www.nissanforklift.com
See Food Master, p. 24
Solutions for you and you alone. No
ceptions.
IIf there h iis one thing hi 0 years off iindustry d i h h us, iit’s ’ that h products d hi h over 50 experience have taught which may have worked in the past may not be sufficient to provide adequate lubrication in the h ffuture. At JAX lentless in our quest st to provide vid you with i h the he mostt inno ive and indi id li d 800.782.8850 JAX, we are relentless innovative individualized llubricant lub i l i d the h lif hi d d i d iincrease production. d i www.jax.com solutions to extend life off your machinery, reduce downtime and Just a our needs are ever-ch i , so is our line of iindustrial d strial llubricants b icants – because af ll as your ever-changing, after all, the th h thing hi ki l i there iis no such as a cookie-cutter solution. See Food Master, p. 76-77
FEX09074JAX.indd 1
November 2011AM31 www.foodengineeringmag.com | Food Engineering | 8/8/07 10:46:17
TECHNOLOGY S O U R C E B O O K
WIDE-MOUTH PET JAR A lightweight replacement for glass for pasta sauces, apple sauce, salsas, jams, jellies and other food products filled at temperatures up to 205ºF, the Amcor 24-oz., round, wide-mouth PET jar is unbreakable, transparent and recyclable. Its 4 horizontal ribs and stiff walls resist vacuum as the product cools, maintaining bottle shape. Blow-trim technology ensures consistent finish dimensions, closure performance and sealing integrity. Amcor Rigid Plastics; www.amcor.com available in single- and double-flex models in inch and metric bore sizes from 0.157 in. (4mm) to 1.750 in. (45mm). All models and sizes feature clamp-style hubs and operate in temperatures from -22°F to 212°F. Zero-Max; 800-533-1731; www.zero-max.com
LINE DIVERTERS
COUPLINGS Designed with 304 stainless steel disc packs and 7075-T6 aluminum hubs, Zero-Max ServoClass couplings provide high torsional stiffness, zero backlash and low hysteresis for precise positioning at speeds up to 10,000rpm. To ensure precise alignment of the assembled components, ISO 4762 CL12.9 corrosion-resistant socket head cap screws are utilized with a carefully controlled assembly process. The couplings are
Used to replace existing manual hose switching stations, Vortex multi-port wye line diverter valves converge or divert materials from one or more sources to one or more destinations. Available in 2- through 8-in. pipe or tube sizes, the diverters can route non-abrasive to moderately abrasive materials, such as granules, pellets and powders. Upon installation, they interface directly with the user’s PLC; the only manual operation is hooking up the inlet of the diverter to the railcar or other source. An operator accesses and directs the switching and/or loading operation through a computer touch screen from inside the facility. Vortex Valves North America; 785825-7177; www.vortexvalves.com
November 2011 | Food Engineering | www.foodengineeringmag.com
TECHNOLOGY S O U R C E B O O K
Service.
FOOD-GRADE EPOXY Independently tested and certified to meet the requirements of FDA CFR 175.300, the Master Bond EP42HT-2FG food-grade epoxy system has been toxicologically evaluated to meet the NSF/ANSI 51.4.1 (2009) standard for food equipment materials. The 2-part epoxy can be used in a variety of applications, such as bonding and sealing metals, plastics, rubber and other substrates. Featuring high resistance to chemicals and many solvents, along with boiling water, fats and oils, it can also be used as a coating for storage tanks, bins, hoppers and other containment vessels. Capable of withstanding conditions over a service temperature range of -60°F to 450°F, the epoxy resists steam, radiation and frozen storage conditions. It comes in half-pint, pint, quart, gallon and five-gallon containers. Master Bond, Inc.; 201-343-8983; www.masterbond.com
BARRIER FILM Designed for powders and nutraceuticals that require an ultra-high moisture barrier, Klöckner Pentapharm ACLAR PA600/02 2-layer laminated barrier film is made with Honeywell 152-micron ACLAR UltRx6000. The film is transparent and non-yellowing and is compatible with existing standard form/fill/seal packaging lines and tooling. Klöckner Pentaplast Group; 540-832-3600; www.kpfilms.com
At ", we take uptime very seriously. Even though " machines are legendary for their reliability, they sometimes need service. Our plant runs day and night and when you need us we are there. Made in the USA. DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934 defranciscimachine.com
[email protected] 321-952-6600
SINE PUMP ICE PREVENTION UNIT Installed inside cold storage and process freezers with temperatures as low as -30°F, the Munters IceDry unit reduces or prevents ice and frost. The unit begins to remove ice immediately and automatically adjusts to keep ice buildup, due to moisture infiltration, under control. Munters; 800-843-5360; www.munters.us
The MasoSine sine pump produces powerful suction with low shear and no pulsation. Large, open cavities allow the transfer of cheese curd with little damage. The pump has only one shaft, one seal and no timing gears for simple inplace rebuilds. It meets 3-A SSI for food sanitation and hygiene. MasoSine; 800-282-8823; www. masosine.com See Food Master, p. 49
www.foodengineeringmag.com | Food Engineering | November 2011
! al er* e w l n rd No ilab ditiorst O a Ad r Fi v A e an You 1
v F Sa OF 5%
Now a Self-Stacking Belt That Won't Break Your Bank Replace your existing self-stacking belts with Ashworth’s NEW ExactaStack™ Drop-in Replacement - Available in all widths including wide belt, tier heights, and mesh configurations for both spliced-in sections and complete belt replacements. No system drive modifications required Turn Key - Expert technical support and full turnkey installation from the belting experts who invented spirals Made in the USA - for fast deliveries and cost savings 1-800-682-4594 to register your Self-Stacking Belts and receive * Call 15% OFF your first ExactaStack order! − Limited Time Offer ™
Increase Capacity & Improve Efficiency - Contact Ashworth Today Ashworth Bros., Inc. +1-800-682-4594 | Ashworth Factory Service +1-866-204-1414
[email protected] | www.ashworth.com
TECHNOLOGY S O U R C E B O O K
DETECTABLE ADDITIVES FDA-compliant Eriez PolyMag additives impart metal detectability, X-ray contrast and magnetic susceptibility into plastic moldings to protect consumers from plastic-contaminated food products. Masterbatch PolyMag additives can be incorporated in returnable plastic containers, pallets, scoops, scrappers, O-rings, gaskets, conveyor belting, drive belting, bucket elevators and more; the masterbatch pellets are available with various carrier resins including ethylene, polypropylene, polycarbonate, nylon, acetal and a flexible elastomer. PolyMag powders can be used for special compounding needs or in foam, thermoset rubber and liquid raw materials. The additives are typically included at 10% to 20% loadings in moldings and extrusions. FDA has offered a favorable opinion of the additives per CTS 75807. Eriez; 888-300-ERIEZ; www.eriez.com
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TEMPERATURE MONITORING LABELS PakSense XpressPDF temperature monitoring labels monitor time and temperature of perishable products during distribution and storage. Approximately the size of a sugar packet, the flat, waterproof labels feature an integrated USB connection point that can be plugged directly into the USB port of a computer. Once connected, the labels automatically generate PDF data files containing a complete time and temperature history including a graph and summary statistics. Light-emitting diodes on the labels flash to indicate a temperature excursion and prompt the user to download full cold chain data via the USB connection. PakSense, Inc.; 208-489-9010; www.paksense.com
Tank Cleaning Devices and CIP Nozzles Reduced Effluent and Reduced Cost
For Rent or Purchasee Energy Sealing
Energy Saving
Rytec’s Turbo-Seal Insulated Door is the world’s fastest, PRVWHQHUJ\HIÀFLHQWKLJKVSHHGGRRU 'LVFRYHUWKH6DYLQJVDW5\WHF'RRUVFRPRUFDOO*25<7(&
Contact Butterworth for moree information: infoormation:
[email protected] 281-821-7300 www.butterworth.com
www.foodengineeringmag.com | Food Engineering | November 2011
35
Sanibel Harbour Marriott
APRIL 22-25, 2012 Sanibel Harbour Marriott, Fort Myers, Florida
02/'2!- s Save the Date — Register by December 31 and Save $400! FOOD AUTOMATION & MANUFACTURING CONFERENCE AND EXPO is the industry’s only event presenting real-world solutions on automation, processing and packaging innovation, sustainability and food safety topics for Operations, Engineering and Manufacturing Executives. Join us in 2012!
W Sunday, April 22
10:00 – 10:30 a.m.
Refreshment Break
12:30 p.m. 10:30 – 11:15 a.m
Golf Tournament
Engineering Keynote: Manufacturing Innovation for Today’s Leaders
7:00 – 8:30 p.m.
Welcome Reception
Dave Haft, Senior Vice President, Sustainability, Productivity and Quality, Frito-Lay Fundamental change is occurring in how food is processed and raw materials are handled as food safety requirements become more stringent. This speaker will discuss how engineering and operations professionals can deliver manufacturing innovation and OEE while controlling capital equipment expenditures.
W Monday, April 23 7:00 a.m. – 3:30 p.m.
Registration 8:00 – 8:10 a.m.
11:15 a.m. – 12:00 p.m.
Welcome
Creating a No-Compromise Operations & Manufacturing Culture
Patrick Young, Publisher, Food Engineering
Neil Ducoff, Founder and CEO, Strategies
8:10 – 8:30 a.m.
When compromise seeps in, it hinders growth, momentum and energy. Allow it to go unchecked, and even very achievable goals can turn into pipe dreams. This speaker will show you how to turn missed opportunities into manufacturing home-runs. No-compromise leadership is a commitment to a higher standard that guides a business culture to extraordinary achievement.
Opening Remarks: The State of Food Manufacturing Joyce Fassl, Editor in Chief, Food Engineering
Theme for Day One: Addressing Manufacturing’s Current Critical Challenges 8:30 – 9:15 a.m.
12:00 – 1:30 p.m.
Keynote Address: The Age of Transparency Michael J. McCloskey, Founder and CEO, Fair Oaks Farm Public and customer demand for greater transparency in food manufacturing is causing many processors to refocus their outlook regarding social responsibility as well food safety. This speaker will address how embracing transparency with science-based technology can lead to profitability.
Lunch Buffet 12:00 – 3:30 p.m.
Expo 1:00 to 4:00 p.m.
Solutions Theater
9:15– 10:00 a.m.
Food Safety Modernization Act: What You Need to Know Now
2:15 –2:45 p.m.
Refreshment Break Stations
Kurt Deibel, Vice President, Quality & Food Safety, HJ Heinz New legislation and resulting enforcement often create questions concerning compliance. This presentation will address the latest trends in food safety management, effective track and trace systems as well as food safety compliance on a global basis.
5:00 – 6:00 p.m.
Expo Reception 6:00 – 8:00 p.m.
Harbour View Barbeque
GOLD SPONSORS
W Tuesday, April 24
W Wednesday, April 25
7:30 a.m. – 1:00 p.m.
7:00 – 8:00 a.m.
Registration
Continental Breakfast
7:30 – 8:30 a.m.
8:00 – 8:15 a.m.
Breakfast
Opening Remarks
7:30 – 9:00 a.m.
Expo
Theme for Day Three: Sustainable Plant and Process Practices
9:00 – 10:00 a.m.
8:15 – 9:00 a.m.
Solutions Theater
Social Responsibility: Addressing Customer and Consumer Concerns
10:00 – 10:30 a.m.
Speaker: Leigh Ann Johnston, CPEA, EHS Training, Communication, & Sustainability Manager, Tyson Foods, Inc. Demonstrating social responsibility is 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. Hear how a leading processor embraces this crucial topic.
Refreshment Break Theme for Day Two: Practical Measures for Improving Plant Performance 10:30 a.m. – 12:00 p.m.
Session A: Packaging Technology 10:30 a.m. Robotics vs Continuous Motion Terrence Southern, Senior Engineer, Flexible Automation, Frito-Lay North America, Inc. 11:15 a.m. Best Practices in Machine Safety Michael Thompson, Golden Peanut Company, a division of ADM Session B: Plant & Process Controls 10:30 a.m.. . . Overcoming the Challenges of Legacy Systems Anass Bennani, MIS Director, Michael Angelo’s Gourmet Foods, Inc.
9:00 – 9:45 a.m.
Wastewater Treatment Paybacks and Benefits The cost and availability of fresh water is becoming an issue for some facilities, and many regulators are mandating organic load reductions. High levels of suspended and dissolved sugars, protein and fat pose a special challenge for food plants. This speaker will show how to achieve cost-effective wastewater treatment. 9:45 – 10:15
Refreshment Break
11:15 a.m. . . . Best Practices in Automated CIP 10:15 – 11:00 a.m.
Improving Your Plant’s Energy Efficiency
12:00 to 1:15 p.m.
Networking Luncheon 1:15 – 2:30 p.m
Ask the Experts Panel: Perfecting Your Continuous Improvement Plan Speakers: Tom Deschler, Vice President, Continuous Improvement, T. Marzetti Company; Tom Lance, Vice President-Operations, The Boston Beer Company; John Mutchler, Executive Vice President, Glanbia USA This special session featuring a panel of food and beverage industry experts will present different viewpoints on various continuous improvement methods such as lean manufacturing, Six Sigma, OEE, KPIs, Kaizen and high performance work teams. These experts will address your top manufacturing challenges.
Energy efficiency and its relation to a product’s carbon footprint are becoming priority concerns for leading food companies. This presentation will cover topics such as energy-efficient lighting, greenhouse gas emissions reduction, boiler optimization and other plant and equipment controls to reduce energy usage. 11:00 – 11:45 a.m.
Leading-Edge Energy Technologies: Assessing the ROI Producing energy from plant waste is an actuality at some food and beverage manufacturing plants. Learn how one innovative food processor is using bio-digester technology to boost its bottom line. 11:45 a.m.
Closing Remarks 2:30 – 3:00 p.m
Refreshment Break
12:00 noon
Conference Adjourns 3:00– 3:45 p.m.
Plant Security Audits: Protecting Your People and Assets Speaker: William L. Ramsey, Director of Corporate Security, McCormick & Company Inc.
The ability to document access-card use, the condition of perimeter defenses and other aspects of safeguards against intentional food contamination will likely be requirements of the Food Safety Modernization Act. Learn how to upgrade your security systems in a costeffective manner. 3:45 – 4:30 p.m.
Plant of the Year Award Join us as we honor the 2012 Food Engineering Plant of the Year Award Winner. Each year, only one food or beverage plant in North America earns this award. 4:30 to 6:00 p.m.
Plant of the Year Reception
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SUSTAINABLE PLANT OF THE YEAR ` Albert DeCima pulls a sample of SunChips as they emerge from the fryer. Casa Grande became the seventh plant in the Frito-Lay network to produce the chips when the new line was completed last year. Source: Reed Rahn.
Frito-Lay Casa Grande Facility Attains Near Net Zero Efficiency was built into Frito-Lay’s Casa Grande plant a quartercentury ago, but the snack maker takes the facility’s energy- and water-conservation systems to a new level with near net zero. `
Kevin T. Higgins, Senior Editor
I
s it feasible for food or beverage production ever to be resource neutral, consuming no more gas, electricity, water and other utilities than what it generates itself? Perhaps theoretically, but not as a practical matter. Still, placing sustainable manufacturing in the context of assuring resource availability so operational capabilities are maintained, regardless of external disruptions, is intriguing. What would a food plant with net-zero impact look like? A close proximity sprawls across 283 acres of the Sonoran desert in Arizona. Part learning lab, part sustainability showcase, the Frito-Lay facility in
Casa Grande is the focus of the snack food manufacturer’s ambitious goal of creating a blueprint for sustained production in a resource-strapped tomorrow. Most of the energy-generation and water-reclamation technology in Casa Grande can be found elsewhere in the Frito-Lay production network, but never before has such a comprehensive infrastructure been created. The result is a plant that pushes the limits of what is possible in energy and water self-sufficiency. Selection of Casa Grande came after an assessment of Frito-Lay’s 37 US facilities by the US Department of Energy’s National Renewable Ener-
www.foodengineeringmag.com | Food Engineering | November 2011
39
SUSTAINABLE PLANT OF THE YEAR
one-tenth the level of municipal water. A third of the crop acreage now supports a field of 18,000 photovoltaic panels, part of a solar array that can generate up to 5 megawatts (MW) of electricity, enough to replace half the power drawn from the electric grid. Thousands of solar panels and dishes make a dramatic visual statement, but the star of Casa Grande’s bid for energy independence is a biomass boiler that can generate up to 60,000 lbs. of steam per hour, matching the output of a gas boiler that now serves as a backup. With the biomass boiler, which burns wood chips and pulp, gas demand is slashed to one fifth previous levels as a ratio of consumption to pounds of finished goods. Energy independence and resource neutrality are the goals Frito-Lay engineers set out to accomplish four years ago. “In one meeting , Group Vice President of Productivity and Sustainability Dave Haft, asked, ‘What if we took the best renewable-energy components at our locations and landed them in one plant?’” recalls corporate engineer Al Halvorsen, senior directorenvironmental sustainability. “What would the plant of the future look like?” The idea sufficiently intrigued PepsiCo CEO Indra Nooyi to warrant a green light for what ultimately became near net zero, a modified label that acknowledges the real barriers of complete resource independence. Nonetheless, the savings achieved in Casa Grande far exceed PepsiCo’s corporate goals (20 percent cuts in electricity and water use over nine years, 25 percent reduction in fuel consumption) and provide a road map to maintaining production in a resource-strained future.
` Ten parabolic mirrors concentrate sunlight and use the energy to power Stirling engines that generate electricity through the compression and expansion of helium gas. Source: Reed Rahn.
40
gy Laboratory. Abundant real estate, Sunbelt location and middle-of-the-pack production size figured in the choice, but the pick also acknowledged the facility’s pedigree. Built in 1984, Casa Grande was a showcase of energy conservation for its day. Its systems and technologies earned it Food Engineering’s designation as 1985 Plant of the Year. Efficiency is relative, and the chip maker holds itself to a higher resource-management standard today. Until a year ago, process wastewater was land applied to former cropland on the plant’s property. With construction of a membrane bioreactor and a low pressure reverse osmosis (LPRO) system, the facility has an advanced filtration infrastructure that reclaims all but the sanitary stream, returning up to three quarters of the water coming into the plant for reuse. Total dissolved solids in the returned water are
November 2011 | Food Engineering | www.foodengineeringmag.com
A sustainable foundation Before any net-zero elements were put in place, Halvorsen’s team optimized the energy infrastructure, improving lighting and compressed-air efficiency and outfitting motors as small as 1hp with VFDs. “The most efficient energy is the energy you never use,” he notes, and front-end improvements meant less water to recycle and a smaller boiler and solar array to install. The groundwork also acknowledged that human behavior is at least as important as technology in manufacturing sustainability. Workers at Casa Grande are among the company’s pacesetters in reducing landfill waste and packaging and production waste below 1 percent. When the landfill-reduction initiative began in 2008, 14 percent of Casa Grande’s waste went to the dump, according to Material Manager Rigo Munoz.
Congratulations, Frito-Lay! Burns & McDonnell congratulates Frito-Lay on winning Food Engineering’s 2011 Sustainable Plant of the Year for its near net-zero Casa Grande facility. We appreciate being a part of the team that helped make the Casa Grande facility successful.
A Total Project Solution We see it clearly.
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Food and Consumer Products Caroline Cooper, 816-822-3831 www.burnsmcd.com/fcp
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SUSTAINABLE PLANT OF THE YEAR
` Mark Duran Sr. is the only operator for nine SunChips packaging lines on his shift. The high-speed lines feature robotic case packers and palletizers. Source: Reed Rahn.
Volunteers drawn from all areas of the facility began analyzing the waste stream and identifying recycling and reuse opportunities. By springtime, waste had been whittled down to “one last stream” representing 0.5 percent, and in May, the plant began diverting it to a California incinerator for conversion to electricity. An assault on production waste commenced soon after. Specialists in lean/Six Sigma, continuous improvement and other areas backed up workers from each shift and the six production lines who vol-
unteered to identify procedural changes. At kick-off meetings, the greater than $1 million savings possible with each percentage point waste reduction was put in tangible terms—two Cadillac Escalades for a point savings on the SunChips line, for example. “We can draw up changeover schedules and hand them out, but the experts are out there on the floor,” notes James Tidwell, 2nd shift corn team leader and one of 10 workers who were among the plant’s original hires in 1984. “We want them engaged and providing input.” Volunteers enjoy bonuses when goals are met, and soft benefits accrue to all for altering behavior. Elevated solar panels form a canopy over the parking lot, shading employees’ vehicles from the desert sun while generating renewable electricity. A recycling vending machine that accepts cans and bottles provides credits workers can redeem for gifts or donate to a veterans organization. Casa Grande also was the first Frito-Lay facility to achieve LEED gold certification for an existing building. Numerous improvements to the existing system were made, including installation of 186 solar tubes for natural lighting. T-12 fluorescents were upgraded to T8/ T5 lighting technology; LED lighting is being evaluated. The facility was expanded last year to 160,000 sq. ft. to accommodate Frito-Lay’s seventh SunChips line. SunChips’ eco-friendly positioning will get a
Investors hedge the solar bet Financial considerations have killed many engineering initiatives, and it could have produced a more modest solar-to-electric element in Frito-Lay’s sustainability project. The investment in photovoltaic solar panels received a big boost from a California renewable-energy company that matches industrial companies with strong credit ratings and the necessary space with investors interested in the solid risk-adjusted equity returns from renewable energy projects. Most of the 5MW solar-electric capacity in Casa Grande derives from two adjacent fields on the northern end of the property. Although the 18,000-plus panels require 36 acres, the facility’s sprawling site easily could have accommodated enough photovoltaic panels to match the plant’s entire electricity demand. Instead, they settled for an infrastructure that generates about 10 million kWh a year and further lowered the company’s financial exposure by striking a deal with Solar Power Partners Inc., San Francisco, to own and manage one of the northern fields.
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November 2011 | Food Engineering | www.foodengineeringmag.com
Negotiating the 20-year agreement with Solar Power was a new experience for Frito-Lay, though it’s old hat for Solar Power, which has executed more than 60 similar projects and has another 30 in the pipeline, according to Todd Michaels, marketing director at Solar Power. Additional negotiations for power purchase involved Arizona Public Service Inc., the electric utility that also provided production-based incentives. The renewable-energy sector is on the defensive, with momentum shifting to the oil industry and others intent on curbing growth in alternative fuels, concedes Michaels. “They see the opportunity to go for the kill,” he says. Nonetheless, “you can do deals without subsidies and still compete” on pricing and investment ROI. Solar Power continues to investigate proposals involving generation of at least 500 kW with companies that have excellent credit ratings, own their own facilities and have appropriate sites. In today’s environment, that often means locations in Arizona, New Mexico, Massachusetts, Hawaii, Puerto Rico and New York.
GE Food & Beverage Solutions
Congratulations!
Congratulations to Frito-Lay’s Casa Grande, Arizona plant for being recognized as Food Engineering’s 2011 “Sustainable Food Plant of the Year.” We’re excited to see the company recognized for setting and working toward ambitious environmental goals. GE Food & Beverage Solutions works closely with organizations such as Frito-Lay to identify and solve their energy and water challenges. With a unique portfolio of innovative technologies and a wealth of industry-specific expertise, we’re working to develop integrated solutions that help our customers realize their own ambitious goals. For more information about GE Food & Beverage Solutions, contact us at: www.ge-energy.com/foodandbeverage
GE’s ZeeWeed* Membrane Bioreactor technology is just one component of the waste-to-value solution offered by GE Food & Beverage Solutions.
*Trademark of General Electric Company
SUSTAINABLE PLANT OF THE YEAR
` More than 18,000 solar panels blanket 36 acres of former crop land owned by Frito-Lay. The single-axis tracking system follows the arc of the sun and generates the bulk of the facility’s 5 megawatts of photovoltaic generating capacity. Source: Frito-Lay.
boost when Casa Grande takes delivery of two electric delivery vehicles. According to Plant Director Jason Gray, recharging will be done directly from one of the photovoltaic arrays, closing the supply chain energy loop. Partners in sustainability Production plays a minor role in food’s carbon footprint. Suppliers, copackers and other supply chain partners are strongly
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November 2011 | Food Engineering | www.foodengineeringmag.com
encouraged to participate in continuous improvement of sustainable practices. Sharing best practices helps all supply-chain partners reduce their resource consumption and encourages development of enabling technology. For example, Frito-Lay redesigned the corn cook process for tortillas, leaving 40 percent of the water in the tanks for the next batch. The idea was embraced by Shearer’s Foods (Food Engineering’s Plant of the Year, April 2011), which was awarded LEED platinum status for its Massillon, OH facility. Shearer’s also commissioned a sealed-cavity oven using infrared ceramic burners from an F-L supplier that helped slash gas consumption 47 percent. Building on those advances, Frito-Lay engineers now are designing additional efficiencies into a specification for a new oven they expect will outperform the Shearer’s unit. With 10 corporate engineers committed to energy management and regulatory compliance, Frito-Lay is able to upgrade standard systems. An example is an air-sweep system that suctions off rinse water from potato chips as they enter fryers. Reengineering the unit to vacuum off the water for reuse low-
ers the fryers’ thermal load because less moisture needs to be boiled off. With 25,000 lbs. of product going through a fryer every hour, the savings quickly add up. Any facility below 33º latitude is ripe for solar-energy harvesting. The question in Casa Grande was scale. With 283 acres of land, the site has room to generate a surplus of electricity, “but when you put pencil to paper, that was not a wise business decision,” says Halvorsen. Instead, a variety of photovoltaic technologies and financing approaches were used, including a partnership with renewable-energy investors (see related story on page 42). Three distinct systems were built: panels mounted on single-axis mechanics to track east to west, three dual-axis tracking systems that align panels with the sun’s point in the sky and 10 units shaped like large satellite dishes and lined with parabolic mirrors that concentrate light and focus it on a Stirling engine that generates electricity from a piston powered by the expansion and contraction of helium. Instead of 10, fabricator Infinia Corp. of Kennewick, WA envisioned a field of hundreds of dishes, but F-L engineers preferred starting small and developing a learning curve. “We love to push the envelope,” Halvorsen says, “but we have to balance the risk while maintaining a cutting edge.” The dishes will power the plant’s electric delivery vehicles. Appropriately, those trucks will distribute SunChips.
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Long travel distances in the Southwest limit opportunities for electric vehicles, and experiments with hybrid vehicles have not fared well. But distribution accounts for a third of the company’s greenhouse gases, and better fuel efficiency is a priority. Fleet-wide performance more than doubled in three years to 18.5 mpg in 2010, with 25 mpg targeted by 2014. Technology and human behavior work in tandem: GPS devices in all 14,126 trucks ensure engines are turned off while drivers are making deliveries, and routes are plotted to reduce miles driven, a best practice Frito-Lay picked up from the EPA’s Smartway program. Drought dread In selecting the most appropriate technology for the site, engineers “looked at the true impact of being a sustainable plant and not just bits and parts,” notes Gray. “We’re really two plants now: We have a chip plant, and we have a utilities plant.” Some alternative energy sources were rejected because of practical considerations. The BOD load from washing potatoes wouldn’t generate much methane, so anaerobic digesters were ruled out. The biomass boiler could have been outfitted with a condensing steam turbine to generate electricity from waste heat, but that would have required cooling tower water, which would undermine water-recovery gains.
NSD TupHTM, A BREAKTHROUGH IN PROTECTION AT A MOLECULAR LEVEL. At last it’s here, a cost-effective and weight-saving alternative to stainless steel for use in the harshest environments. NORD has redefined surface protection. NSD TupHTM is a true innovation in corrosion resistant cleanable sealed surfaces. Molecular conversion of the aluminum alloy provides our drive equipment with all the protection your application demands. All of this at a fraction of the price you have been forced to pay for stainless steel. Introducing NSD TupHTM, the better solution you have been asking for is finally here. You can immediately start saving big money on protection without compromising quality. Contact us today and find out how you can profit from NORD reinvention.
www.nord.com INNOVATION BEYOND THE ORDINARY www.foodengineeringmag.com | Food Engineering | November 2011
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SUSTAINABLE PLANT OF THE YEAR
` Considerably larger than a gas-fired unit, the plant’s biomass boiler generates up to 60,000 lbs. of steam an hour, the same as the boiler it replaces but using wood scraps and agricultural waste. Source: Frito-Lay.
Creating an integrated system that minimized demand on all utilities was the goal. From an economic perspective, reducing water consumption is difficult to justify. As a global manufacturer, Frito-Lay already operates in water-stressed regions, and with availability becom-
ing a concern in areas in North America, managers reasoned now is the time to develop a water-recycling knowledge base. “When is the best time to figure out how to operate a plant with 70 percent less water?” Halvorsen asks rhetorically. “It’s not in a drought; it’s right now.” A membrane bioreactor from GE with storage capacity of 1.2 million gallons was the first major installation in the net zero project, coming online in May 2010. According to GE, the reactor reclaims 648,000 gallons of water a day, a figure that fluctuates with production. The system enables the plant to reuse half the water it taps from the municipal waterworks. Another new technology is the LPRO system downstream from the bioreactor. Project Engineer Sam Tajahmadi says fouling was an issue initially, but the installation of carbon filtration tanks as a pretreatment step helped increase reuse rates to 65 percent. Installation of larger, permanent tanks is expected to take reuse to 75 percent. The same technology, which operates at pressures below 200psi, is being applied at Frito-Lay’s plant in Tingalpa, Australia.
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SUSTAINABLE PLANT OF THE YEAR
While corporate management never established a budget for net zero, “that didn’t mean an open checkbook,” Halvorsen emphasizes. “ We had a 10-year record of energy-savings projects that drove dollars to the bottom line,” and net-zero investments were expected to generate a reason-
able return. “With unlimited funds, I could take any plant off the grid,” he adds. “The question is, where is the balance between net zero and generating a return to the company?” Payback calculations assumed no increases in energy costs—a conservative approach with electricity, though the decline in
` Rigo Munoz places empty beverage containers into a vending machine that tracks his deposits and lets him redeem points for prizes or donations to a veterans assistance group. While the so-called Dream Machine is a plant expense, it does stimulate involvement in the zero-landfill initiative.
natural gas costs highlights the uncertainty in projecting commodity prices. Water comprises 80 percent of a potato’s mass. If that water could be captured and reused along with the ex haust’s heat, facilities like Casa Grande would become net water producers. Whether that becomes reality or remains science fiction, net zero puts Frito-Lay in the company of the US Army and engineers engaged in contingency planning for resource-stressed situations. The military regards net zero as a force multiplier by pursuing sustainable practices so that operations aren’t compromised in the event of external disruptions. The stakes may not be as high for a food plant, but a manufacturer’s future survival may hinge on the sustainable defenses put in place today. ❖ For more information: Todd Michaels, Solar Power Partners Inc.,
See Food Master, p. 68
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November 2011 | Food Engineering | www.foodengineeringmag.com
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GREEN SERIES ` In this soy protein isolate facility, energy monitoring systems keep track of electrical and thermal energy used in the process. Source: Rockwell.
Indispensable Energy Audits Energy audits and management can increase the bottom line, but to be effective, the job is never done. ` Wayne Labs, Senior Technical Editor
F
ailing to be a good steward of WAGES (an acronym for water, compressed air, gas, electricity and steam) not only wastes energy, it also eats into profits. Indeed, being green can help a processor stay alive in this era of increasing energy and utilities costs. “Our foresight is that [geographical] areas of low power cost and subsequent subsidies are a thing of the past,” says Alex Daneman, president and CEO of Hench Control, a provider of energy management and industrial refrigeration systems. Consequently, processors are reviewing their energy profiles because energy is no longer cheap
no matter where it’s purchased, and it’s becoming a bigger part of production costs, according to Robert Gates, GE Intelligent Platforms global technical manager. Customer expectations also play a role in the decision to go green. “The real drivers for energy conservation are coming from consumers and big box retailers,” says Gates. “Both see energy conservation as the right thing to do for the environment and the bottom line.” According to Daneman, processors should consider three important points as they look for ways to audit energy usage and decrease energy costs:
www.foodengineeringmag.com | Food Engineering | November 2011
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GREEN SERIES
` This is one of 15 cooling rooms where the Spara EMS (energy management system) from Powerit Solutions automates demand control and demand response (DR) at Four Star Fruit in Delano, CA. The system balances DR and energy efficiency with the operational requirements of the facility. The Spara system is set up to precool the room, offsetting all-at-once demands and at peak hours. Source: Powerit Solutions.
1. Monitoring energy usage alone does not solve the problem. 2. Making the right adjustments after monitoring is crucial to lowering energy costs. 3. The energy audit/management process is not simple, nor is it a one-time occurrence. A new model is also available for processors to use to audit energy usage within their plants, says Bill Schiel, director of business development at Invensys Operations Management and US delegate to the ISO 50001 Standards Committee. The June 2011 ISO 50001 Specification treats energy audits/management much like the ISO 9001 quality standard. “This is a management system—the same as a quality system. You develop a policy and define actions, metrics and improvements, and then do checks. It’s a ‘plan-do-check’ cycle for continuous improvement,” says Schiel. The standard is now available as a template. With it, processors can take a more systematic, top-down approach to defining and reaching a goal, for example, to reduce energy usage by 15 percent over five years, according to Schiel. “This is an auditable process where an ISO certification can be obtained.” While the new ISO standard provides a good template for energy audits, many processors that have been doing energy audits for some time already follow the same system. Steven Hawkins, Stellar’s director of automation, breaks it down into five steps: assessment (establish an energy usage baseline and determine goals for energy reduction), diagnostics and estimates (define the scope and estimate ROI), corrective action (engineer and install a system to monitor energy and utilities usage), monitoring (track energy usage and generate daily status reports) and ongoing maintenance (keep replacement parts readily available for the monitoring system). “It is often said, ‘If you don’t measure it, you can’t manage it,’” says Paul Stiller, director of energy management for Summit 52
November 2011 | Food Engineering | www.foodengineeringmag.com
Energy Services. “I would add measuring is not managing. I see food processors investing large sums of money in elaborate energy metering and reporting systems before they know what information is needed and why,” he adds. According to Stiller, it is essential to begin with the end in sight, design the management reports and clearly understand how they will be effectively used before investing in a metering system. The continuous nature of energy audits, management and action cannot be over-emphasized. “We do not do short-term or one-time audits,” says Bill Holmes, principal, Holmes Energy LLC. “Our philosophy is: Instead of spending money on one-time audits, [clients should] spend the money to install energy-monitoring instrumentation. From then on, the client has a detailed, continuous and unbiased energy audit that shows when and where every energy dollar is spent within the facility.” Holmes adds that the instrumentation uncovers hidden opportunities for low-cost/no-cost savings with ROIs possible within weeks or months. An initial audit tied to utility bills is essential, however, to determine what the ROI is likely to be on an energy management system. For example, “Our assessments combine operational and financial analysis,” says Bob Zak, general manager and president of Powerit Solutions. Assessments include analysis of electric bills and historical kW interval data; evaluation of opportunities to participate in demand response or other incentive programs; collection of detailed data about the facility’s main processes, largest electrical loads and the facility in general; and a site audit covering the entire facility and all processes, from receiving raw materials to final product shipping. Obvious energy users It would seem that many of the “low-hanging fruit,” or the obvious energy improvement opportunities have already been tackled by processors, but that isn’t necessarily so, according to many energy experts. “The most common energy-wasting problems in food and beverage facilities are inefficient lighting, lack of variable frequency drives (VFDs) on fans and pumps and steam process inefficiencies,” says Danielle Marquis, SmartWatt Energy corporate marketing manager. While transitioning pumps and fans to VFDs usually represents a first step to saving energy, a good second step is to evaluate the means of control of older equipment, recommends Darryl Wernimont, POWER Engineers’ market specialist for
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GREEN SERIES ` Top: Mariah’s meat packing plant’s daily electric consumption consisted mostly of refrigeration (66 percent). Bottom: Because of defective automatic defrost valves in the refrigeration equipment, the system ran continuously, chalking up a tremendous false load placed on the power grid and costing an exorbitant sum. Source: Opto 22.
Another slant on the rooftop air handler is the intentional disabling of the unit’s economizer, says Dan Homan, Rockwell CEM project manager. Homan’s seen lots of them. As a result, the equipment is using expensive mechanical cooling when free cooling from outside air is available. By repairing the economizers, upgrading the control system and using enthalpy comparison of return air and outside air to determine when switching to outside air is more efficient, processors can save energy by avoiding the use of mechanical cooling.
food, beverage and consumer products. For example, the basic heat exchanger may perform as effectively as it did 20 years ago, however, the means of control, monitoring and verification probably need to be brought up to date. Other savings opportunities, according to Marquis, could include adding night setback and other scheduling systems where appropriate, replacing/repairing steam traps, enhancing manufacturing processes (e.g., heat recovery from ovens or compressors) and replacing boilers and/or chillers, rooftop HVAC units, building and roof insulation and windows. What’s on the roof is often out-of-sight and out-of-mind. “One large food production facility in a northern climate had abandoned older HVAC equipment in place,” relates Brad Heeres, principal and director of engineering services at GMB Architecture + Engineering. The units had steam heating coils. To prevent the heating coils from freezing during an extreme cold snap, steam valves were manually locked in a partially open position. While the solution was intended to be temporary, when the cold snap ended, the steam valves were forgotten. GMB’s engineers observed the condition in June while on site reviewing equipment related to another project. Plant management was alerted. The air handling units were more appropriately decommissioned and the steam coils disconnected, says Heeres. 54
November 2011 | Food Engineering | www.foodengineeringmag.com
Psst … It’s not a secret Speaking of cooling, some employees have been known to use compressed air for personal cooling, which is not only wasteful but potentially very dangerous, says Paul Humphreys, Atlas Copco vice president of communications and branding. While it’s easy to detect an air leak if you can hear it, it’s the inaudible leaks that really cost processors money. Humphreys says about 80 percent of air leaks detected in compressed air systems aren’t audible, and a single quarter-inch leak at 100psi costs more than $2,500 a year. Depending on pressure requirements and energy costs, by some accounts, this can escalate to as much as $8,000 a year per leak, says Humphreys. Piping systems more than five years old have shown leaks and need to be scrutinized. Humphreys notes there are a couple of ways to reclaim energy from air systems. For example, air compressors generate heat that can be reclaimed to preheat water for boilers, warm areas of the plant floor or loading docks, or even aid in heating water for clean-up/washdown purposes. In many plants, compressed air is maintained at a higher pressure than necessary. One facility manager, according to Humphreys, wanted to lower energy costs but avoid the ire of workers who complained about pressure drops. Beginning at 110psi, the manager dropped his system’s output by 1psi per day until he got a complaint. When he reached 99psi, someone complained, so he raised the pressure to 100psi and settled there with no complaints. According to Humphreys, every 2psig reduction cuts energy consumption by 1 percent. “Flagrant energy waste often results from over-serving the need,” states Stiller. “For example, we recently encountered a food plant drying compressed air to -68°F dew point. This increased the cost of air by 30 percent (about $145,000 annually).” The client had installed special desiccant dryers years ago to meet a need that no longer existed. Not-so-obvious energy users Hidden energy wasters are frequently found in efforts to solve other problems, says Heeres. In one case, an uninsu-
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GREEN SERIES lated plate-coil heat exchanger was the suspected cause of an overheated room. A review of the entire system revealed that direct discharge of steam to the room from a condensate receiver overflow line discharging to a trench drain in the space was the primary culprit. This led to the review of the operation of other condensate
receivers in the facility. Action taken resulted in the addition of condensate coolers used to preheat the product and improvements in the condensate venting and overflow system—all of which provided an under-threeyear payback, while improving the operation of the plant condensate return system, reducing boiler make-
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up water requirements and fixing the problem of the overheated space. “Steam traps are a hidden energy waster—most customers are surprised to learn that there are incentives available to repair or replace steam traps, one of the most maintenance-intensive mechanical components of a facility,” says Bryan Genevick, SmartWatt Energy project development engineer. “A major grocery chain was surprised to learn that we could take over the replacement of hundreds of steam traps per month—and that its utility provided incentives for us to do so. We have also been able to reduce the need to use a chiller to cool 85°F water in parts of customers’ processes by implementing heat transfer to use this hot water to heat their warehouse.” Keep your cool! While steam, of course, is an important utility, “chilled media” is an energy-based utility that Schiel thinks should be added to the WAGES list—especially in a food plant where chilling is as important as heating or cooking. This concept of cool, sending a refrigerant around a plant to be used like any other utility, has to be created with other energy sources, primarily electricity. One of Zak’s processor clients used to run its cooling systems continuously, including the fans. After an energy audit, which found the problem, and the implementation of Powerit’s energy management system, the processor’s systems are automatically turned off or down when a threshold temperature is reached, and the fans are slowed with VFDs or cycled off to prevent warming the space from the heat generated by the fan motors when they’re not needed. Peak demand and use reductions resulted in 13 percent lower costs. At an older Mariah meat packing plant, the refrigeration system accounted for two-thirds of the plant’s total electric consumption, says Arun Sinha, Opto 22 director of business development. This was discovered after adding Opto hardware and Holmes’s AutoPilot energy information system to track the plant’s energy usage. The plant’s existing refrigeration equipment should have had more than twice the capacity to do the job. Yet, electric bills were exceedingly high.
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GREEN SERIES “Knowing the utility costs associated with specific systems and areas within our plant helped us to determine that it was no longer competitive in our industry,” says Mariah’s General Manager Joe Brands. “When the data showed that the utility costs associated with parts of our operation were more than twice what they would be at one of our new plants, the need for major changes was clear.” The problem was traced to the cooling coils in the freezers, which had their own automatic defrosting system. Periodically, hot refrigerant gas was blown through the cold coils to prevent ice buildup. Unfortunately, the old automatic valves that regulated the defrosting process had stopped working in a partially open position and continuously allowed hot gas to warm the coils, requiring the refrigeration system to run almost continually. The processor had budgeted $100,000 for new transformers plus tens of thousands more to add refrigeration capacity until the monitoring system honed in on the problem. Once the valves were repaired, the refrigeration system got a big break, and so did the processor by cutting its electric usage by 600 KWhr per day, an annual savings of $250,000. Decreased water usage saves energy Processors that use water as their primary ingredient know something others may not consider until an audit is done. That is, decreasing water usage provides several benefits, according
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to Schiel. “There are companies like Anheuser-Busch that attack their water problem first—because it’s going to help fix energy problems. Think of it this way,” says Sheil. “If we can reduce the water intensity of our operation, we don’t have to buy as much water. [ If we don’t buy the water], we don’t have to clean it or preprocess it. We don’t have to heat it; we don’t have to cool it. We don’t have to treat it or pay the waste costs.” Matutano-PepsiCo Group, located in Spain set out to reduce its energy consumption and water usage, according to the ISO 14001 environmental quality standard. The snack food maker installed a Schneider energy management system consisting of 41 PM710 electrical power meters and 17 Endress+Hauser flowmeters to monitor water, plus other instrumentation to monitor gas, air and steam. It also installed Vijeo Citect supervisory software and Vijeo Historian to monitor the WAGES usage in the plant. Before the Schneider project was accepted, several other auditors offered their services, but none of them included water usage. Water usage at this facility included several complex circuits. With the instrumentation in place and the system providing details on WAGES usage, the processor has been able to cut water usage by 38 percent and expects to cut energy consumption 20 percent by 2015. Monitoring WAGES during non-production times—like the weekend—can provide some unexpected results. According to Homan, one processor identified some unusually high
November 2011 | Food Engineering | www.foodengineeringmag.com
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GREEN SERIES water usage over the weekend, which was traced to an out-of-the-way hand valve that had been open for months—maybe even years. By turning that valve off, the processor saved thousands of gallons of water that had previously been dumping down the drain. One of Gates’ clients discovered through monitoring energy consump-
tion and utilities during both working and non-working hours that water leaks from the locker room faucets and showerheads contributed 10 percent to the plant’s water consumption. Take the load off The cost of peak demand service sometimes puts a heavy penalty on electric
High performance in a small footprint. The latest addition to the SORTEX E range, the SORTEX E1D offers a high performance sort in a small footprint. It has been designed to bring the benefits of larger sorters to smaller processors while delivering a high quality sorting in the freezing process. A combination of technologies and options allow for processors to tailor the sorter’s inspection system to their specific needs. It’s capable of inspecting product for discolored or misshaped product, subtle blemishes, FM or EVM, or any combination thereof. www.buhlergroup.com Buhler Sortex Inc. 209.983.8400
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November 2011 | Food Engineering | www.foodengineeringmag.com
bills. When situations are known, the remedy is to add VFDs and soft motor starters and make sure large motors are not started at full load or simultaneously. Once a motor control system has been installed and operational, “temporary alterations to resolve urgent operating issues,” as Stiller calls them, can be expensive in the long term. In one case, a processor took a series of 40hp pumps off variable speed control to stabilize pressure in a product header. That was in 1993; no one ever went back to determine the root cause of the problem. Stiller says adjustments were made to a PLC program and solenoid valve in 2010, restoring variable speed operation. Running on fixed speed for those 17 years increased operating cost by well over $100,000. “By the way, I support temporary alterations; they are essential to keep product flowing,” says Stiller. “The key is to follow up, understand the real problem and find the best long-term solution.” One of Zak’s clients had an ingredient mixing process that randomly occurred during different shifts, usually when the operator felt like it. Unfortunately this process often occurred when other equipment was making demands and/or when energy was most expensive. The problem was fixed by implementing an energy management system (Spara EMS) that tightly controlled whether the process could be started during these less-thanfavorable peak power times when rates were the highest. Smart technology and remote monitoring systems represent the next step in curbing energy costs, especially electrical energy, says to Tom Konicke, McKinstry operations manager, energy and facility services. Used reactively or proactively, these smart systems leverage and expand on technology already embedded within many facilities and equipment. McKinstry has the ability to monitor and control from a distance critical energyusing systems at clients’ facilities to obtain the best real-time rates. The ultimate control for high-demand loads is smart grid, a system where utilities communicate directly with heavy, energy-consuming equipment
in industrial applications and ultimately homes as well. “What we are starting to see occur in various regions, is that processors, via various smart grid integration options, will have options that will allow them to run certain processes during times of lower energy rates,” says Gary Khort, Iconics vice president of marketing. First star ting in bui ldings, then expanding into manufacturing operations, utilities are beginning to provide dynamic rate data (via smart grid protocols, public web ser vices) and rate offers for the short term (next hour, next four hours, eight hours etc.), according to Khort. In addition to having the option to operate when energy is at a lower cost, processors will also be offered live feeds telling them how green the current energ y supply is. They will be able to operate their selective processes and build inventor y, when energy is most green, to improve their sustainability goals. Today, an energy audit is not just good thing to do; it’s indispensable to operating efficiently. Many issues can be discovered and corrected automatically by an auditing/monitoring/control system. But, if you don’t make energy savings an inherent part of everyone’s work culture, you could f ind yourself slipping backward as employees opt for a quick fix to keep production running. Like a continuous improvement program for quality or food safety, energy has to be treated with the same importance. ❖
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FLOORING ` Sanitation routines and other factors dictate the type of flooring used in food and beverage plants, though increasingly the choice is seamless coatings. Source: Cornerstone Flooring.
Know thy installer Polymer science presents food and beverage manufacturers with many floor covering options, but performance often hinges on the expertise of the people installing them. ` Kevin T. Higgins, Senior Editor
B
lues/folk singer Maria Muldaur warbled, “It ain’t the meat, it’s the motion.” The sentiment can be applied to industrial flooring, with seamless toppings serving as meat and the installation crew providing the motion. Epoxy, resin and urethane-based floor toppings are a growing trend in food and beverage plants, with polymer flooring suppliers launching forays into segments previously considered off limits. A recent trade show for dairy processors attracted a handful of seamless flooring formulators hoping
to lure dairies away from tile and acid-resistant brick, at least in nonprocessing areas. Food companies’ focus on improved sanitation as a fundamental element of food safety has resulted in second and third looks at polymer flooring. Previous experiences soured many manufacturers on these materials, which straddle the science of paint technology and the mason’s craft. “If you don’t have a power trowel, you are a painter, not a flooring installer,” says one cement contractor. The best option is the installer with expertise in both disciplines. That
www.foodengineeringmag.com | Food Engineering | November 2011
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FLOORING
` An installer spreads sand while his coworkers continue to spread a cementitious urethane compound on top of a concrete floor. If insufficient sand is deposited, long-term failure is likely. Source: Surface Solutions Inc.
scenario increases the likelihood of material recommendations based on the best solution, not the topping the installer happens to sell.
Proper preparation and application of synthetic materials are vital and must be preceded by careful assessment of the conditions of use. Unfortunately, those steps are not always followed, resulting in premature failure. “The evaluation step is crucial,” insists Ron Puszynski, president of Chicago area installer Concare Inc. Once a compound is selected, Puszynski advocates securing a letter of certification from the material manufacturer. “If you get the manufacturer involved that way, you can validate the appropriateness of the selection,” he points out. Unqualified and careless installers have tarnished the image of seamless floor compounds, complains Steven Hess, president of Indianapolis-based Surface Solutions Inc. “You can have the best product in the bucket, but if you don’t put it down right, you’ve got nothing,” says Hess, who winces at the installers’ image of “fat guys with sanders on their belts” who either don’t know or don’t follow proper procedures. For example, some coatings require installers to broadcast 1.5 lbs. of sand per square foot to
The marks of good housekeeping Lean manufacturing initiatives are notable for their bottomup assessment of plant practices—quite literally, in the case of flooring, when 5S teams order the placement of pallet outlines and directional information on the factory floor. Installers of industrial flooring are tapping a growing business for cautionary warnings and position markings that are part of a floor’s top coat. “Corporate safety departments drive a lot of it,” acknowledges Ron Puszynski, president of Concare Inc., Melrose Park, IL, but interest in waste elimination is playing an expanding role. As an adjunct to kaisen events and other continuous improvement efforts targeting processes and procedures, lean practitioners are taking a hard look at how housekeeping adds to or reduces waste. The 5S technique lends itself to reevaluation of floor organization. A manufacturing best practice from Japan, 5S is awkwardly translated into English as sort, set in order, shine, standardize and sustain. Masking tape can suffice for entrylevel directionals, but many firms are taking the concept well beyond. “They’ll mark where a sanitation cart goes, where the pallet goes,” says Puszynski. “The objective is creating an automated process for the people in the plant.” Permanent markings might not be an option if it means taking an area out of production. However, advances in material sci-
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` Directional and other information are being embedded in plant floors as part of 5S initiatives. A thin coating that cures immediately after exposure to ultraviolet light minimizes the disruption to a plant’s normal activities. Source: Concare Inc.
ence are removing that obstacle. For example, a thin-film coating from the Netherlands cures instantly with the help of a machine resembling a lawnmower that brings UV light close enough to the film to be effective. The coating, developed by Royal DSM N.V., emits near-zero levels of volatile organic compounds. “Thin film isn’t for everything,” Puszynski cautions, “but it can be helpful to lean teams seeking improved factory flow and worker safety.”
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` Concrete is the preferred substrate for seamless coatings, though other flooring can be coated. A deteriorated acid brick floor (left) was coated with cementitious urethane (right) to produce a more sanitary appearance. Source: Sherwin-Williams.
enhance a coating’s ability to withstand thermal cycles. “Some people don’t want to sweep that much sand off at the end of the day,” he says, and they use less than the
specified amount. The difference is invisible to the naked eye, at least until pinholes and other faults appear later. Industrial clients shoulder some of the blame. As the variety and complexity of flooring options have expanded, food companies and others sometimes fail to establish proper specifications. If all stakeholders in the project are not involved in the inspection and evaluation phases, the likelihood of an unfavorable outcome increases.
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November 2011 | Food Engineering | www.foodengineeringmag.com
` Projects that take a line out of production cause manufacturers to cringe and make the decision to install fast-curing floors easier. Source: SaniCrete.
Some suppliers tackle installation by training and deploying their own installers. “You’re only as good as the guys who install the floor,” reasons Keith Kwasny, founder and president of Farmington Hills, MI-based Sanicrete. He is gradually adding installation crews, requiring new workers to spend a year as a laborer before serving a one- to two- year apprenticeship. Some suppliers are instituting more stringent certification programs, often augmented with material-specific training by the formulator. BASF Corp., which pioneered cementitious urethane toppings under its Ucrete brand, established a master contractor program in the early 1970s, when Ucrete first entered the market, according to Ashley Davidson, product marketing manager in the firm’s US headquarters in Cleveland. The program has been beefed up in recent years, says Davidson, and contractors must be certified in order to purchase the company’s floor coatings. Best-fit materials If Know Thy Installer is the first commandment of industrial flooring, Know Thy Application surely is the second. Perfor-
mance expectations and operating conditions dictate material selection, and the number of options is increasing. For food and beverage, some installers opt for cementitious urethane, a blend of urethane and cement, over
www.foodengineeringmag.com | Food Engineering | November 2011
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Food & Beverage Industry Flooring Suppliers Atlas Mineral and Chemicals Inc. 1227 Valley Rd., P.O. Box 38 Mertztown, PA 19539 800-523-8269 www.atlasmin.com BASF Construction Chemicals-Building Systems 889 Valley Park Dr. Shakopee, MN 55379 952-496-6000 www.buildingsystems.basf.com Blome International Inc. 1450 Hoff Industrial Dr. O’Fallon, MO 63366 636-379-9119 www.blome.com ChemMasters 300 Edwards St., Madison, OH 44057 800-486-7866 www.chemmasters.net Concare 2081 North 15th Avenue Melrose Park, Illinois 60160 708-681-8800; 866-CONCARE www.concare.com Cornerstone Flooring 750 Patrick Place, Brownsburg, IN 46112 800-659-7699 www.cornerstoneflooring.com
Corro-Shield International Inc. 7059 Barry St., Rosemont, IL 60018 847-298-7770 www.corroshield.com
Protective Industrial Polymers 140 Sheldon Road, Berea, OH 44017 440-243-4560 www.protectiveindustrialpolymers.com
SlipNOT Metal Safety Flooring 2545 Beaufait St., Detroit, MI 48207 800-754-7668 www.slipnot.com
Crossfield Products Corp. 3000 E. Harcourt St. Rancho Dominguez, CA 90221 310-886-9100 www.crossfieldproducts.com
Kagetec Industrial Flooring Systems 309 Elm Ave. SW, Montgomery, MN 56069 612-435-7642 www.kagetecusa.com
Stonhard Inc. One Park Ave., Maple Shade, NJ 08052 800-257-7953 www.stonhard.com
SaniCrete 24535 Hallwood Court Farmington Hills, MI 48335 248-893-1000 www.sanicrete.com
Surface Solutions Inc. 5689 W. 73rd St. Indianapolis, IN 46278 866-858-4080; 317-388-8000 www.surfacesolutionsusa.com
Sherwin-Williams Protective & Marine Coatings 101 Prospect Ave. Cleveland, OH 44115 800-524-5979 www.sherwin-williams.com
Tennant Company 701 N. Lilac Minneapolis, MN 55440 763-540-1200 www.tennantco.com
Dur-A-Flex, Inc. 95 Goodwin St. East Hartford, CT 06108 860-528-9838 www.dur-a-flex.com Fortified Systems Inc. 126 Eisenhower Ln. N. Lombard, IL 60148 630-916-0438 www.fortifiedsystems.com
Sika Industrial Flooring Division of Sika Corp. 201 Polito Ave., Lyndhurst, NJ 07071 800-637-7793 www.sikafloorusa.com
Garon Products Inc. P.O. Box 1924, Wall, NJ 07719 732-223-2500 www.garonproducts.com High Performance Systems 22 Hillcrest Blvd. Warren, NJ 07059 800-928-7220 www.highperfsystems.com
Silikal 609-B Fertilla Street, Carrollton, GA 30117 888-830-1404 www.silikalamerica.com
Tnemec Co. Inc. P.O. Box 165770, Kansas City, MO 64116 800-Tnemec-1, 816-326-4254 www.tnemec.com
For a complete of flooring suppliers, see Food Master or visit. www.foodmaster.com
The industry’s only pre-filed hard bound catalog listing equipment, supplies and services to the food and beverage industry is only a phone call away. No need to work with an incomplete vendor list or wade through hundreds of consumer listings online. The Food Master is the most comprehensive reference source for Plant Operations, Engineering, Manufacturing and Packaging executives.
To order your personal copy, call Ann Kalb at 248-244-6499 or go to www.foodmaster.com
68
November 2011 | Food Engineering | www.foodengineeringmag.com
FLOORING
epoxy coatings. The material’s ability to withstand thermal shock as the plant cycles through hot water washdown and refrigerated operating conditions, as well as its abrasion and impact resistance, make it the material of choice in the harshest environment. On the other hand, processing areas for shelf-stable and further-processed foods usually don’t require high-pressure washdown, in which case epoxy may be appropriate. “There are different microbiological requirements for a meat plant than a bakery than a dairy,” points out Paul Brawley, operations manager at Cornerstone Flooring, Indianapolis. Food safety considerations dictate a floor’s performance requirements, and epoxy coatings often provide a cleanable and serviceable alternative. In warehouses and employee welfare areas, polyurethane can be costly overkill. Time spent coating a substrate and waiting for it to cure is time lost to production. Formulators have responded to manufacturers’ desire to return an area to production as quickly as possible with fast-curing finishes, including a thin film that cures instantly with ultraviolet light (see related story on page 64). Surface Solutions’ Hess says some clients are unwilling to wait the two days necessary to apply and seal a topping like Ucrete HP and opt instead for Ucrete HF, a heavy-duty coating that also allows a one-day turnaround. “It’s more functional than aesthetic,” he says of HF, and the manufacturer’s thermal specs are broader than HP’s. For extreme cold, methylmethacrylate (MMA) is the resin of choice, according to BASF’s Davidson. MMA sets up in less than two hours at temperatures as low as -20°F, though VOCs are an issue. BASF produces MMA and epoxy coatings, but cementitious urethane accounts for 80 percent of the company’s industrial flooring applications, Davidson estimates. The material boasts a coeff icient of thermal expansion (CTE) that closely mimics that of concrete.
Coefficient of friction (COF) is another barometer of flooring performance. Though it sounds counterintuitive, John Crowley of Garon Products Inc. says gloss and semigloss urethane cements developed by his firm deliver greater COF than the
typical matte finish. Another Garon innovation is an epoxy with nanoparticles of less than 0.1 micron that is more resistant to abrasions and increases strength without compromising clarity, according to Crowley, vice president of the Wall, NJ firm.
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www.foodengineeringmag.com | Food Engineering | November 2011
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FLOORING
Fortified food defense For years, food companies have greeted antimicrobial additives for floor coatings with a collective shrug, but suppliers and installers say food safety considerations are making manufacturers more receptive to the idea. BASF is making an antimicro-
bial based on silver ion-technology available, backed by research on its efficacy. “Anybody can add an antimicrobial and say it is going to be effective,” says Davidson. “Food companies want to go a step beyond, but first they want to understand what it means in terms of effectiveness.”
Washdowns without washing out.
Our flooring is designed to stand up to caustic cleaning agents, tolerates temperatures from -100° F to 220° F and provides the best defense against microbes that can take a bite out of your business. Keep your production line rolling with less maintenance, better compliance and less downtime – choose flooring designed specifically for the food manufacturing industry. For more information, call us or visit our website. Dur-A-Flex, Inc. 95 Goodwin Street East Hartford, CT 06108
800-253-3539 DurableFoodProcessingFloors.com See Food Master, p. 52
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November 2011 | Food Engineering | www.foodengineeringmag.com
“Mold won’t feed on the plastic” in seamless floor coating, allows Pat Scudder, president of Protective Industrial Polymers (PIP) in Berea, OH, “ but what about a divot or fracture where microbes find a food source?” His firm is introducing a concrete pretreatment with an antimicrobial additive that has been demonstrated to be effective in inhibiting mold and bacteria growth in the substrate. The additive also can be included in the flooring’s top coat to create an antimicrobial system, he says. PIP developed an epoxy primer to address vapor intrusion from a cement substrate, replacing air in the cement with a colloidal gel. Chemists started experimenting with various antimicrobial additives, gradually increasing the ratio of additive to epoxy until tests could confirm the gel’s effectiveness. The CTE rate increases, which means the concrete doesn’t expand or contract as much as it normally would, helping to extend the floor’s life. While that functional benefit seems compelling by itself, the antimicrobial additive is attracting the most interest, Scudder says. Describing it as “a belt and suspenders preventative solution,” Concare’s Puszynski says his firm has recommended the material to end users because of its ability to penetrate six inches or more into the substrate, thereby stabilizing the infrastructure. Additives and pretreatments that improve a floor ’s performance have merit, but many within the flooring business itself are skeptical about antimicrobial elements. “To me, this is still a marketing gimmick,” says Klaus Huenermann, technical director for Silikal America, a Carrollton, GA division of a German manufacturer of methacrylate resins that Huenermann describes as “enhanced MMA.” “It’s way beyond epoxy in terms of durability and gripability,” he adds. Gripability is particularly important on ladders and platforms, two common applications for the plasma stream deposition of metal alloy particles done
by Detroit-based SlipNOT Metal Safety Flooring. The difference between “the peaks and valleys” of those particles determines the COF of the slip-resistant coating , says Christina MolnarMetrose, v ice president of business development. For food plants, a Grade 1 coating is recommended for bakeries and other sites where ease of cleaning also is desired, while Grade 2 is appropriate for a packing house where grease and water make a high COF a priority. Absent a COF standard, comparisons of the traction of different floor coverings are difficult, notes MolnarMetrose. The type of footwear worn in the plant further complicates the issue, she adds. That said, SlipNOT usually defers to the OSHA 88 standard for quantifying COF. Most of its food application coatings rate 0.85 or greater. No end user has ever disclosed the impact of better traction on slips and falls, but some report productivity improvements when workers are more sure-footed, says Molnar-Metrose. Installation isn’t an issue for Slipnot, which fabricates plates or coats drain covers and other components in its facility and then ships them to the food company or its equipment fabricator. For many other flooring suppliers, ensuring the integrity of the installation work is an ongoing struggle. “We are selling a capital investment that should last more than five or 10 years, so we don’t sell materials to anyone else,” says Brawley of Cornerstone, which maintains its own installation teams. The oversight is particularly important in food plants, where proper clothing and food safety protocols must be observed. Painters typically bring xylene and other chemical solvents to job sites, but xylene is strictly prohibited in food manufacturing facilities. Ensuring work teams adhere to those restrictions and requirements is almost as important as following the proper installation steps, he says. Grout in tiles and brick is a breeding ground for bacteria, and many food
manufacturers are replacing those durable floor coverings with seamless coatings. Suppliers have differing opinions of whether a seamless topping can be poured over existi ng b r i c k , o r i f t h e o l d f l o o r i ng must be removed. But there’s no
disagreement on the importance of qualified and conscientious installers. Regardless of the performance requirements or the material type, the service life of a new floor is contingent on the workers who paint or trowel the material. ❖
YOU ARE AS SAFE AS THE
FLOOR YOU WALK ON
SlipNOT ® 's slip resistant premier stainless steel product line creates a low maintenance, easy to install, sanitary solution for slippery areas in food p ro c e s s i n g f a c i l i t i e s . S l i p N O T ® i s e n g i n e e re d t o w i t h s t a n d t h e e x t re m e heat of cookers and steamers and cold of cryogenics, as well as daily washdowns and caustic cleaning agents.
Green Products
313.923.0400 | 800.754.7668 | www.slipnot.com |
[email protected]
SlipNOT Metal Safety Flooring
®
[
SlipNOT® manufactures slip resistant metal flooring products that are designed to increase safety and decrease your risk exposure.
SlipNOT® Metal Safety Flooring products may be covered by one or more of the following patents; 5,711,119,6,839,951, and 6,863,932.
s l i p r e s i s ta n t s ta i n l e s s s t e e l f l o o r i n g Additional patents pending. ® 2010 W.S. Molnar Company. All rights reserved.
www.foodengineeringmag.com | Food Engineering | November 2011
71
No problem with BLOCK-BUSTER™ bulk bag conditioners
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CHILE UK AUSTRALIA SOUTH AFRICA
DRY PROCESSING TECHNOLOGY Focus on POWDER & BULK OPERATIONS Wayne Labs, Senior Technical Editor
Tea blend time and degradation cut with rotary mixer
`
Tumble-turn-cut-fold mixing action yields 100% batch uniformity in less than three minutes.
W
` (Left): An employee loads ingredients into the mixer. (Top, right): Mixing flights produce a tumbleturn-cut-fold mixing action that yields 100 percent batch uniformity in less than three minutes. (Bottom, right): A variety of natural flavors can be added to the tea via an internal spray system. Source: Munson Machinery.
hen Choice Organic Teas was founded in 1989 by Granum Inc., it launched the first exclusively organic tea brand in the US. The company offered four choices of organic teas— Green, Ban-cha, Twig and Oolong. Today, it offers more than 75 varieties of USDA-certified organic, sustainably grown teas and herbal infusions. In 1990, the processor was using a 10-cu.-ft. capacity, food-grade, modified cement mixer to blend up to 30 lbs. of tea per batch. During the mixing process, the mixer had to be stopped and opened several times, both to add flavoring and to address unblended areas, which significantly slowed the blending process. “The modified cement mixer lacked a baffle system unlike the mixer we use today,” explains Rod Hanson, Choice Organic Teas quality assurance manager. “Because of this, there was a dead zone in the middle of the mixer where the tea would not properly blend, and this area had to be manually scooped and stirred, after which the machine could be restarted.” Long mixing cycles degraded the delicate tea leaves, while frequent stoppages and low capacity meant that an entire workday was lost blending enough batches to yield 240 lb. of blended organic tea. As the company grew, it added increasingly sophisticated bagging equipment and eventually replaced its blender with a 15-cu.-ft. capacity MX15-SS mini rotary batch mixer from Munson Machinery. “The Munson mixer revolutionized our blending operation,” says Eric Ring, Choice Organic Teas purchasing manager. “It allowed us to do large amounts of blending with no ribbons of
non-blended ingredients, yet gently enough that it didn’t damage the tea.” The stainless steel Munson blender uses a gravitydriven mixing process, which employs internal mixing flights that produce a tumble-turn-cut-fold mixing action. The processor runs the mixer continuously for 15 to 20 minutes per batch to prevent stratification of ingredients throughout loading and final discharge with no residuals. Average weights for each batch of tea range from 150 to 300 lbs. “Teabag cuts, which are finer than leaf tea, can be mixed at higher weights—up to 320 lbs.— because they’re stronger and heavier,” says Ring. “Leaf teas are mixed in smaller batches to protect the leaf.” Some blends have only two to three ingredients, while others require 10 to 12. “We choose hundreds of different organic-certified ingredients from select tea gardens and vendors worldwide,” says Hanson. “We have specific recipes for our blends that are formulated pre-production for our many bagged tea and whole leaf offerings. Our master blender adheres to these blend sheets when weighing out specific ingredients for each blend and knows, through experience, the blend time necessary for each batch.” Internal spray lines built into the mixer allow for a wide, even spray of natural flavors. “We choose from a variety of nozzles based on the viscosity of the flavor,” says Ring. “Using the internal spray system and a specific nozzle, we are able to pressurize the flavor and apply it widely and uniformly as the tea tumbles, resulting in uniform distribution with no saturated areas.” The internal spray system is also used for cleaning the blender between batches. “We have a nozzle that allows a strong flow of our own special formula for flavor neutralization and cleaning between batches,” adds Ring. ❖ For more information: Steve Knauth, 315-797-0090,
[email protected]
www.foodengineeringmag.com | Food Engineering | November 2011
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DRY PROCESSING TECHNOLOGY
has a cam-operated drive mechanism and spring-loaded gates that open and close alternately, preventing air seepage and maintaining proper pressure. Aerodyne; 800-358-7546, ext. 2; www.dustcollectorhq.com
COMPACT FILTERS
Product Delivered.
Just Right. Segregation Free. Damage Free. Abrasion Free. Dense Phase Vacuum Conveying. Safe, sanitary, easy-to-use maintain and install,
VALVES FOR CHUNKY MATERIALS Aerodyne’s GatorGate double-dump valve can be used to discharge chunky, fibrous and abrasive material efficiently from dust collection systems. The valve works with low-pressure air or gravity-fed systems where standard rotary valves are prone to failure. The double-dump gate valve
Tri-Mer’s Tri-Flow filters deliver HEPA-like performance with a MERV 16 rating. The compact filters provide a high-performing alternative to bag, cartridge and pocket filters, which are rated typically MERV 10-13. A greater increase in filtration area vs. volume is achieved in comparison with sleeve-type, high-efficiency filters. The filter design provides in-line, pulse-jet cleaning and maintains a low operating pressure drop. Filter efficiencies of 99.999 percent on 0.5 micron and larger particles (by weight) are typical. The filters are self-supporting and are manufactured using proprietary filter media tailored to the application. Tri-Mer Corp.; 623-271-0929; www.tri-mer.com
Volkmann high quality, vacuum conveying systems will deliver your product just right, no matter where it needs to go.
No Contamination
BFM® Flexible Sleeve
Snaps In Place
Dust Tight
Easy To Clean
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No Tools
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Perfect Fit Every Time! See Food Master, p. 108
877-BFM-FLEX POWDER-SOLUTIONS.com
609-265-0101 www.volkmannUSA.com
November 2011 | Food Engineering | www.foodengineeringmag.com
tors can plug in the recipes for multiple formulas, set an automatic preset value, measure the weight of the dry product and flow rate of the fluid, and control the speeds of the vibratory hopper and pump. Atlas Automation; 585-227-1110; www.atlas-automation.com
VALVES WITH BLOWTHROUGH FEEDERS/ AIRLOCKS
POWER BLENDER The Atlas powder blender is designed and configured to break up clumps found in dry bulk product before entering a fluid to ensure equal distribution. Made of stainless steel and designed to fit any space, the blender consists of a funnel, vibratory hopper, feeder, scale, mixing tube, level, pump and meter. Opera-
WE TAKE OUT
ACS Valves’ BT Series valves with blowthrough feeders/airlocks ensure optimal bulk density and throughput of hard-toconvey materials such as fine powders and flakes that can easily over-aerate and reduce material feed efficiency in highpressure, pneumatic conveying applications. The feeder/airlock architecture decreases excess aeration of the material during conveying with an integrated vent port on the return side of the valve housing, which automatically vents air leakage. ACS Valves; 800-655-3447; www.acsvalves.com
See Food Master, p. 73
DynaPure Mist Collector ®
Entrained Oil
Ba g a n d Ca r t r idg e C olle ct o r s • Mis t Co lle cto r s W e t Du st C o l l e c t o r s • S id e A cce ss Ho u sin g s
AND
• The DynaPure system captures mist down to the submicron particle size. • The DynaPure Collector can be easily installed on or adjacent to the machine generating the mist. • All models conform to OSHA noise standards. ®
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For further information call 1-800-477-1214 or email
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www.foodengineeringmag.com | Food Engineering | November 2011
DRY PROCESSING TECHNOLOGY
SANITARY ROTARY BATCH MIXER SCREENER FOR OVERSIZE FRACTIONS Kason’s Model K72-1K-SS Vibroscreen screener discharges oversize particles 360° around the periphery of an “External Kascade” circular screening deck. The screener is intended for screening wet or dry bulk materials containing a large percentage of oversize fractions at higher rates than are attainable with conventional screeners. As material is fed onto the center of the screening deck, on-size particles pass through the screen and funnel through a lower discharge chute. Oversize particles flow outward in a spiral pattern and cascade over the periphery of the circular screen onto a spiral vibratory trough. Kason Corporation; 973-467-8140; www.kason.com
MATERIAL MASTER ™
Munson Machinery’s Model 700-TH-40-SS sanitary rotary mixer gently blends batches of ingredients in parts as small as one per million with 100 percent uniformity in less than 3 minutes and evacuates all of the batch. The unit features a retractable inlet for rapid, thorough washdown; a stationary discharge; and a rotating drum with proprietary mixing flights that tumble, turn and fold material, imparting minimal energy to the batch while achieving uniformity in 2 to 3 minutes, regardless of disparities in the bulk densities, particle sizes or flow characteristics of batch ingredients. Munson Machinery Company; 800-944-664; www.munsonmachinery.com
BULK BAG DISCHARGER
NEW Patented design delivers superior performance Choosy about bag handling? We hear you. Take a closer look at the features of our Material Master Discharger: i
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Ask about our complete line of drum and container dumpers, bulk bag ¿llers and bulk bag conditioners.
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November 2011 | Food Engineering | www.foodengineeringmag.com
DRY PROCESSING TECHNOLOGY
Reliable Food Grade Synthetic Lubricants
trolley to lift and position bulk bags without the use of a forklift. A spout-lock clamp ring forms a high-integrity seal between the clean side of the bag spout and the clean side of the equipment, while a telescoping tube maintains constant downward pressure on the clamp ring and bag spout, elongating the bag as it empties to promote complete discharge. Flexicon Corporation; 888-353-9426; www.flexicon.com
For consistant food grade lubricant quality, buy from a company that is NSF H1 and ISO 21469 CERTIFIED. Summit Industrial Products is one of the fast growing synthetic food grade lubricant manufacturing companies in the US.
Try us out and see why!
VIBRATORY DRIVE
SKID-MOUNTED BAG DISCHARGING SYSTEM The Flexicon bulk bag discharging system with integral pneumatic conveying system transfers material from bulk bags to silos and other storage vessels. This positive pressure pneumatic system fills bulk storage facilities on islands or other locations unable to receive large volumes of bulk material by rail or bulk truck. The discharger portion includes a cantilevered I-beam with electric hoist and
Witte’s twin-shaft vibratory drive features a proprietary design that produces a linear vibration that delivers consistent motion to its large, high-capacity fluid bed dryers, coolers, screeners and conveyors. Developed for smooth, high-volume, continuous operation, the new twin-shaft drive offers a low-maintenance approach that replaces gears, drive springs, counter-reacting bases and crank arms with belts, oversized spherical roller bearings and an enlarged eccentric counterweight. The Witte Co.; 908-689-6500; www.witte.com
DON’T SETTLE FOR “GOOD ENOUGH” In my facility, having pumps I can count on is important. Downtime is not an option. ISO 21469 ISO 9001:2008 KOSHER CFIA HALAL
800.749.5823 www.klsummit.com
SUMMIT
INDUSTRIAL PRODUCTS
I need quality sanitary transfer equipment that can pump anything from purees to peanut butter –
Graco SaniForce® is my only choice. I know my business and my pumps, and I will not settle for anything less than the best. Contact Graco today:
1-877-844-7226 www.gracosaniforce.com See Food Master, p. 65 November 2011 | Food Engineering | www.foodengineeringmag.com
BULK HANDLING/FEEDING SYSTEM K-Tron’s material handling and continuous feeding system features ActiFlow, a material flow aid that prevents bridging and rat-holing of cohesive mate-
rials in loss-in-weight feeder hoppers. The K2-ML-D5-T35 Quick Change feeder runs in combination with a Model 2410 stainless steel receiver for sanitary pneumatic conveying applications. This fully automated system handles enhanced material-centered applications. The Model T35/S60 quick-change feeder works with applications requiring rapid changeover of materials and fast cleaning. The feeder allows the removal of the entire feed hopper with screws in place and replacement with a second unit. The single-screw feeding elements handle free-flowing powders, granules and other non-flooding materials while the twin screw elements control floodable powders and more difficult, sticky or hard-to-flow materials. The Model 2410 vacuum-sequencing, central powder receiver conveys fine bulk materials, and is available in 2 versions for either general keep-full conveying or loss-inweight feeder refill applications. K-Tron; 856-589-0500; www.ktroncan.com
ROTARY BATCH MIXERS Gentle, homogeneous blending and uniform coating with no segregation on discharge. Lab to 600 cu ft sizes
SCREEN CLASSIFYING CUTTERS Proprietary rotary cutter blades with replaceable inserts cut tough materials into precise sizes with minimum fines
PIN MILLS
Medium to fine grinding of powders, flakes and granules to as low as 400 mesh
DRY INGREDIENT FEEDERS CONTINUOUS FEEDING & BATCHING RIBBON BLENDERS
LOSS-IN-WEIGHT/VOLUMETRIC
Ribbon, plow or paddle styles to 1000 cu ft at low cost
ROTARY LUMP BREAKERS FLEXWALL®
SCREW REMOVAL
MICRO FEEDER
FLEXWALL® Single-Screw Feeder Twin-Screw Feeder
MICRO FEEDER Twin-Screw Feeder Gram by gram
Screw removal from rear of feeder
VIBRATING TRAY Non-pulsing flow Good for fast batching
VIBRATING TRAY
www.brabenderti.com Toll Free: 888. 284. 4574 | Contact:
[email protected]
Visit website for details on this and other Munson equipment including V-Cone Blenders, Continuous Rotary Blenders, High Intensity Blenders, Attrition Mills, Hammer Mills and Shredders.
Munson Machinery Co., Inc. 210 Seward Ave. Utica, NY, 13503 USA 800-944-6644 In NY: 315-797-0090
[email protected]
Z-0885
www.foodengineeringmag.com | Food Engineering | November 2011
Dual rotor mill reduces compacted, lumpy, hard and friable materials
DRY PROCESSING TECHNOLOGY
MAGNETIC, METAL DETECTABLE SCREEN CLEANERS Sifter Parts & Service provides FDA-approved polyurethane screen cleaning balls and cubes to prevent sifter screens from clogging with product. Polyurethane balls are more abrasion resistant than screen cleaners made of other materials and provide a longer service life. Unlike rubber or neoprene, the polyballs are non-porous and oil, moisture and chemical resistant. Sifter Parts & Service; 800-367-3591; www.sifterparts.com
SANITARY DUMPER
The industry’s only pre-filed hard bound catalog listing equipment, supplies and services to the food and beverage industry is only a phone call away. No need to work with an incomplete vendor list or wade through hundreds of consumer listings online. The Food Master is the most comprehensive reference source for Plant Operations, Engineering, Manufacturing and Packaging executives.
To order your personal copy, call Ann Kalb at 248-244-6499 or go to www.foodmaster.com
80
National Bulk Equipment’s processspecific sanitary bulk container dumper is designed and built to the particular sanitary operating processes and practices of an application to ensure optimal compliance contribution (OCC). The construction of the sanitary bulk container dumper meets the FDA, cGMP definition for cleanability according to 21CFR110.40, and has design features that proactively facilitate thorough cleaning and meet or reduce target cleaning times. Features include the elimination of internal angles, corners and dead spaces to avoid accumulation of contaminants; angled-planes, rounded-radius framework, highly finished plate and stand-offs to reduce material build-up and speed material and moisture runoff away from product contact areas; and component frameworks cut from plate to eliminate exposed fasteners, joints and crevices common with tubular assemblies. The sanitary container dumper, which can run continuously, is constructed of 6- x 4- x 5/16-in. structural framework, and has a lift carriage capacity in excess of 2,500 lbs. per 135° rotation. Hermetically sealed connectors and components are protected from corrosion and high temperature. US- and European-compliant controls enable simple integration to any facility’s SCADA system. National Bulk Equipment, Inc.; 616399-2220; www.nbe-inc.com
November 2011 | Food Engineering | www.foodengineeringmag.com
FM 2012 Its Here Full.indd 1
10/24/11 10:49 AM
BULK BAG MATERIAL CONDITIONER Material Transfer’s Material Master bulk bag material conditioner makes it easier to discharge bulk bags that have solidified, hardened or agglomerated. The conditioner uses hydraulically actuated, twin heavy-wall, tubular steel pivoting conditioning arms. Each conditioning arm features V-shaped tubular steel breaker profiles that safely and efficiently return solidified materials to a free-flowing state. Material Transfer; 800-836-7068; www.materialtransfer.com
POWDER CONVEYOR Piab’s piFLOWi powder vacuum conveyor system consists of 25 standard parts that can be combined to create more than 2,000 configurations depending on the application’s requirements. The conveyor system has a full opening to maximize throughput, is ATEX dust classified and comes equipped with the company’s COAX cartridges to produce vacuum. The system meets ASTM 304 specifications and features modular design. Applications include powder and granular transfer, form-fill-seal equipment, big bag loading and unloading, drum/bag filling and emptying, and operation in explosive atmospheres. PIAB; 800-321-7422; www.piab.com
LOW-PROFILE SEPARATOR SWECO’s Model LA low-profile separator incorporates a single large, vertically mounted motor to induce a sifting motion across the screen plane. The frames of the separator are mounted on rubber isolators compared to springs in conventional low profile and other standard separators. Additionally, the separator runs at higher G loadings and speeds than many traditional low-profile separators. High rates of speed can be attributed to the sifting action that the singlemotor design achieves. The LA separator’s pure horizontal, high G motion increases the capacity of the undersize product passing through the screen while allowing oversize material to exit the separator. SWECO; 800-807-9326; www.sweco.com
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SPECIAL ADVERTISING SECTION
LI TER A T UR E & P R O D U C T R E V I E W Xtreme Steam by AmeriVap Systems
Ashworth
The Xtreme Steam unit from AmeriVap Systems is a portable dry steam vapor unit that offers totally organic cleaning and sanitizing. The unit reduces water consumption, increases sanitation standards and is ideal for cleaning and sanitizing packaging/production equipment, electrical control panels, conveyor belts, robotics, motors, scales, drains, chains, and so much more. AmeriVap also introduces the Houdini Automatic Conveyor Belt Cleaner and Sanitizer, which is powered by Xtreme Steam generators.
Ashworth’s new website provides on-demand access of conveyor belt information for many specific requirements. With over 900 pages, the user-friendly interface provides a simple way to find features, benefits and specifications for a wide range of applications. Ashworth - The Conveyor Belt Experts Phone: 1-800-682-4594
[email protected] www.ashworth.com
Phone (404) 350-0239; Web www.amerivap.com
BETE Fog Nozzle’s HydroWhirl™ Orbitor – A New “Revolution” In Tank Cleaning BETE Fog Nozzle’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. BETE Fog Nozzle, Inc. 50 Greenfield Street Greenfield, MA 01301 T (413)772-2166 • F (413)772-6729 www.bete.com
[email protected]
Clarion® PM Hi-Temp Food Machinery 100 Greases
Clarion® Food Machinery Grease, No. 2 Clarion® Food Machinery Grease, No. 2 effectively lubricates most machinery used to manufacture, process, package and store food products in a range of temperatures from 0 to 275°F (-18 to 135°C). With a smooth, buttery and adhesive texture, the grease is water insoluble and very resistant to water washout. No pigments are used, therefore it is nonstaining. Registered NSF H1, the grease is available in NCGI Consistency No. 2. For more information or to purchase Clarion Food Machinery Grease, No. 2, visit www.clarionlubricants.com.
Clarion Lubricants 1293 Eldridge Parkway, Houston, TX 77077 Phone: 855-MY-CLARION (855-692-5274) URL: www.clarionlubricants.com Email:
[email protected]
Reserve your FREE 2011/12 Cole-Parmer® General Catalog
Clarion PM Hi-Temp Food Machinery 100 Greases are specifically blended for lubrication of machinery used in the food industry such as rolling elements, plain bearings, and in automatic and centralized lubrication systems. The greases operate well at high and low temperatures, provide excellent water resistance, effectively prevent corrosion even in water and contain food adhesions and cohesion properties. This product is suitable for incidental food contact by the FDA and available in NLGI Consistency No. 1 and 2. For more information or to purchase Clarion PM Hi-Temp Food Machinery 100 Greases, visit www.clarionlubricants.com.
Select the latest fluid handling, laboratory research, industrial process, and electrochemistry products to help you get your job done! More than 2,600 pages feature brand names such as Masterflex®, Oakton®, Polystat®, and many more.
Clarion Lubricants 1293 Eldridge Parkway, Houston, TX 77077 Phone: 855-MY-CLARION (855-692-5274) URL: www.clarionlubricants.com Email:
[email protected]
To reserve your copy, call 800-323-4340 or visit ColeParmer.com/8280.
®
Cyclone Belt Washer Cyclone C-RH Belt Washer Rotary Head Belt Washer for Open Mesh Belts
SPRAY HEAD MOUNTED ON SPIRAL INFEED
CATCH PAN MOUNTED UNDER SPRAY HEAD
PORTABLE CART MOUNTED TO SPRAY HEAD
OPTIONAL LINEAR HEAD FOR SOLID BELT APPLICATIONS
Cyclone Rotary Head belt washing applications include Spiral Conveyors, Freezing Tunnels, Meat Fryers/Ovens or any other type of belt that allows for drainage. Reduce down time, remove allergens, increase belt life and save water and labor with a Cyclone Belt Washer. Designed for maximum cleaning effectiveness, the Cyclone’s rotating spray head – with speed and pressure adjustment – cuts and removes stubborn soils from both the top and the bottom in one pass.
Vibratory Selection Guide Reduce down time, remove allergens, increase belt life and save water and labor with a patented Cyclone Belt Washer from Douglas Machines. Designed for a wide variety of open mesh spiral conveyors, freezer tunnels and oven belts, the portable Cyclone spray head features high pressure rotating nozzles to cut and remove stubborn soils from both the top and the bottom in one pass.
Eriez’ complete vibratory product line presented in an easy-to-use manner, with a broad overview to help select the proper equipment. Eriez’ innovations provide for a large array of feeding and conveying equipment options.
Douglas Machines Corp. 2101 Calumet Street • Clearwater, FL 33765 P: 727-461-3477 E:
[email protected] W: www.dougmac.com
Visit www.eriez.com or call 1-888-300-3743.
Comes with a portable cart that allows you to move from one belt to another for quick clean up. Consider an optional “Air Blast” Blower with portable air knives to aid in drying, an optional catch pan to collect water for convenient routing to drain and optional Linear Spray Head for solid belt applications.
• Works With or Without Hot Water MEET TODAY’S HIGH STANDARD OF CLEANLINESS AND SANITATION FOR BOTH CUSTOMERS AND REGULATORS. • Reduces Spiral Belt Tension STANDARDIZE YOUR CLEANING PROCESS. SAVE VALUABLE WATER, LABOR, ENERGY AND CHEMICAL EXPENSE. • Cleans Without Degreasers or Caustics • UL/CSA/CE Approved Control Panel REDUCE DOWNTIME. INCREASE PRODUCTIVITY • Cleans Metal or Plastic Belts • Does the Work of Two Men
• Uses just 3 - 4 GPM at 1500 to 2000 PSI • Portable Spray Head & Cart • Removes Fats, Sugars, Oils & Allergens • One Year Parts Warranty
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SPECIAL ADVERTISING SECTION
LI TER A T UR E & P R O D U C T R E V I E W SINGLE-TRIP BULK BAG UNLOADER
Fortress Phantom STEALTH Metal Detector
New Single-Trip Bulk Bag Unloader relies on the user’s forklift or plant hoist to lower single-use bulk bags onto a four-bladed bag piercing knife that cuts the bag bottom from seam-to-seam, promoting complete discharge. The hopper charges the intake adapter of an integral Flexible Screw Conveyor that handles free- and non-free-flowing bulk materials from large pellets to sub-micron powders.
The STEALTH Metal Detector is the latest addition to Fortress Technology’s PHANTOM series. The evolutionary design offers full backwards compatibility, ensuring spare parts and upgrades are readily available for existing systems. Features of the new STEALTH unit include powerful digital signal processing (DSP) technology which provides high-speed precision detection, while ultra-sensitivity levels detect the smallest metal contaminants. This user-friendly interface also has an optional USB port for easy access to QA Reports.
Flexicon Corporation 1-888-353-9426
[email protected] www.flexicon.com
Fortress Technology Inc. Tel: 1-888-220-8737 or 416-754-2898
[email protected] www.fortresstechnology.com
Hapman Releases Powder and Bulk Solids Material Density Guide
Gentle and Efficient PD Pump Fristam’s FL II Series positive displacement pumps use a proven design to provide gentle product handling, complete cleanability, high efficiencies, and ease of maintenance. Nine pump models and a full range of options are available to match process needs precisely. Pressures up to 170 PSI. Viscosities up to 100,000 cps. Flow rates up to 380 gpm.
Hapman has released a new bulk material density guide consisting of powder and bulk solids. A comprehensive online reference tool to help customers determine the correct specifications in designing a system. It is readily available on every product page It offers easy access to hundreds of material densities and is especially user-friendly since it includes a compound search option that quickly identifies the specific material customers are looking for.
Fristam Pumps USA www.fristam.com/usa 800-841-5001
For more information, go to www.hapman.com. Print copies in standard format can be requested by calling 1-800-427-6260.
The RotoDrawer™ Magnetic Separator
I.J. White Spiral Systems This new 6 page brochure from IJ White describes the technical services being offered for spiral cooling and freezing systems. These services include system relocation, training programs on preventative maintenance, sanitation procedures and system trouble shooting. IJ White Systems 20 Executive Blvd Farmingdale, NY 11735 Phone: 631-293-2211 Fax: 631-293-3788 E-Mail:
[email protected] www.ijwhite.com
Martin Brothers, Inc. Heat Exchangers Martin Brothers stocks all makes and models of nickel scraped surface heat exchangers with a re- chromed inside diameter tube. Martin Brothers re-chromes the tube inside diameter plating to a finished 0.006” thickness. We also provide technical, troubleshooting, custom design and customer services. We are an international supplier and the only company in the world dedicated to remanufactured and reconditioned scraped surface heat exchangers. Please check out website, www.teammartinbrothers.com, for available equipment and prices.
The RotoDrawer™ magnet features a motorized, cylindrical configuration of Rare Earth Magnetic Tubes on a horizontal plane that continually rotate through a gravity fed product stream. The magnets, with the assistance of an incorporated set of unique splitter bars that serve to further break up clumps of product, keep the flow moving through the housing while capturing any ferrous metal contamination and purifying the product. Industrial Magnetics, Inc. Boyne City, MI USA p: 888.582.0821 • w:magnetics.com e:
[email protected]
MATERIAL HANDLING PRODUCTS Whether you need screw conveyors, drag conveyors, bucket elevators, or have special material handling needs, Martin’s comprehensive product line is sure to have the answer. New brochure provides an overview of material handling product offering and custom capabilities. For your free brochure contact: Martin Sprocket & Gear, Inc. (817) 258-3000 FAX 817-258-3333 www.martinsprocket.com www.foodengineeringmag.com | Food Engineering | November 2011
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SPECIAL ADVERTISING SECTION
LI TER A T UR E & P R O D U C T R E V I E W SCREEN CLASSIFYING CUTTER SCC-15B Screen Classifying Cutter cuts hard, soft and fibrous materials into controlled particle sizes from granules down to 20-30 mesh with minimal fines, at rates to 500 cu ft/h (14 cu m/h). Proprietary helical rotor design with dozens of cutter heads attached to a helical array of staggered holders (interconnected parallelograms) continuously shear oversize materials against twin, stationary bed knives.
Newark Wire Cloth has made available a SANICLEAN Strainer catalog containing the most complete information on inline and side inlet sanitary strainers and wire mesh overscreens. The inline strainer section contains assembly information, component parts and perforated support cores. The side inlet strainer section contains information on assembly, component parts and support cores. The wire mesh overscreen section includes SKS overscreens, wedge wire strainer elements and filter socks and retaining rings.
Munson Machinery Company, Inc. 800-944-6644
[email protected] • www.munsonmachinery.com
Contact Richard Campbell at Newark Wire Cloth 800-221-0392 or
[email protected]
DILBERT™ NEW HORIZONS® in Products for Sanitary Applications Version No. 27 Contains over 180 pages of the latest information on top selling products for the sanitary food, beverage, pharmaceutical, bio-medical and related process markets or lab operations, including the Digital RTD Thermometers with NEMA 4 Enclosures for wash down, sanitary, and marine applications. Omega Engineering One Omega Drive • Stamford, CT 06907 Toll Free: 800-826-6342 • Tel. 203-359-7815 www.omega.com
Perfex Corporation
Opto 22 Now you can monitor and control your automation system from your iPhone, iPod touch, or iPad. The Opto iPAC app gives authorized automation engineers and control technicians quick access to status and values for all Opto 22 SNAP I/O and control variables, tables, and flowcharts. Ideal for commissioning, debugging, responding to alarms, and remote installations. Available on the App Store. Opto 22 800-321-6786 www.opto22.com REID SUPPLY FOR INDUSTRIAL PRODUCTS
Perfex Corporation has become the nation’s principal manufacturer of unique and innovative cleaning tools designed for controlled environments. Our products are designed to be cost effective, easy to use, as well as heat, bacteria and chemical resistant. TruCLEAN™ Cleaning Systems isolate contaminants to ensure the delivery of unadulterated cleaning agents. Constructed of high-grade stainless steel, TruCLEAN™ Components are easy to maintain and compatible with gamma, ETO and autoclave sterilization. Perfex Corporation 32 Case Street • Poland, NY 13431 Toll Free: 800-848-8483, Tel. 315-826-7471 • www.PerfexOnline.com
SEALMASTER ENGINEERED INFLATABLES Improve processing efficiency with Seal Master Engineered Inflatables. Custom built, fabric-reinforced and fully molded, they are widely used for sealing for close tolerance applications and to fill voids and compensate for irregular surfaces. Actuators, bladders, bags and plugs also featured. Use for mixing, drying, cooling, granulation, coating and other applications. FDA compliant compounds. Designer assistance offered. SEAL MASTER CORPORATION 368 MARTINEL DR., KENT, OH 44240 Ph:800-477-8436, Fax: 330-673-8242 www.sealmaster.com email:
[email protected]
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Newark Wire Cloth
November 2011 | Food Engineering | www.foodengineeringmag.com
Visit ReidSupply.com for your FREE PRINT CATALOG, FREE CAD, AND FAST, EASY ONLINE ORDERING. Interesting categories include Knobs, Handles and Hand Wheels; Clamps and Workholding; Tooling Components; Fasteners and Hardware; Leveling Devices and Vibration Control; Material Handling; Bearings and Power Transmission; Metalworking; Tools, Maintenance and Shop Supplies; Pneumatics and Hydraulics; Structural Systems; Safety; and Packaging and Shipping. See them all right now at ReidSupply.com.
Reid Supply Company Industrial Products Since 1948 (800) 253-0421 Web: ReidSupply.com SEW-EURODRIVE New DR Series Motors Learn about the new AC motor series available in three levels of efficiency; standard, high-efficiency and NEMA Premium®. Each model of the DR series is customizable to meet any type of application including high duty cycling. This brochure presents features and benefits as well as technical specifications. www.sewmotortruth.com SEW-EURODRIVE 1295 Old Spartanburg Highway Lyman, SC 29365 www.sewmotortruth.com 864-439-7537
SPECIAL ADVERTISING SECTION
LI TER A T UR E & P R O D U C T R E V I E W SlipNOT® Metal Safety Flooring
New Expanded Line of Tank Cleaning Equipment
SlipNOT® manufactures slip resistant stainless steel flooring products. Products are registered by NSF International for use in food processing facilities. From floor plates, bar grating, ladder rungs and rung covers, to platforms, drain covers and stair treads; SlipNOT® is the one-time answer for increased productivity and safety. Products are manufactured to specifications.
Additions to the TankJet® line from Spraying Systems Co. include several high-impact tank cleaners for removal of stubborn residues, motorized units that provide a targeted directional spray and compact nozzles for cleaning small containers. Request Catalog 15 and get complete details on dozens of tank cleaning solutions for tanks up to 100’ (30 m) in dia.
SlipNOT® Metal Safety Flooring 2545 Beaufait Street Detroit, MI 48207 ph: 313-923-0400/800-754-7668 fx: 313-923-4555 web: www.slipnot.com
Spraying Systems Co. PO Box 7900 Wheaton, IL 60187-7901 1-800-95.SPRAY www.tankjet.com
More Choices, More Solutions with SPX It’s hard to find a more comprehensive portfolio of processing equipment anywhere else. Many of our designs incorporate patented features and our research and development efforts continue to produce groundbreaking technologies. You’re sure to find answers in the SPX Flow Technology Food and Beverage brochure that will improve plant performance, increase profitability and enhance the value of your brand. SPX Flow Technology 611 Sugar Creek Road, Delavan, WI 53115 Tel: 800-252-5200 Fax: 262-728-4904 Email:
[email protected] www.spxft.com
Triple/S Dynamics, Inc.
TEKLEEN® Automatic Filters Inc. Tekleen automatic water filters are maintenance free filters that will save you time & money otherwise spent in the labor of cleaning and replacing screens, bags, and cartridges every day the hard way. The filters automatically self clean without external power requirements and use as little as four gallons of water to backwash. 2672 S. La Cienega Blvd. Los Angeles, CA 90034 Phone: 1-800-336-1942 or 310-839-2828 Fax: 310-839-6878 Email:
[email protected] Web: www.tekleen.com
Omnilube® Food Grade Lubricants The Slipstick® Horizontal Motion Conveyor from Triple/S Dynamics doesn’t compromise food quality or present a safety hazard. The low impact motion preserves the integrity of the product conveyed, while the elimination of external springs, belts, and rollers ensures a safer and more sanitary operation. Triple/S Dynamics, Inc. P. O. Box 151027 • Dallas, Texas 75315-1027 214.828.8600 • Fax 214.828.8688 Email: sales @sssdynamics.com www.sssdynamics.com
Urschel
The Omnilube® family of lubricants from Ultrachem, Inc. is a complete line of premium quality food grade synthetic oils and grease. These products meet all of the requirements of the USDA and FDA H-1 regulations, 21 CFR 178.3570, and conform to the requirements of NSF. The Omnilube® line of lubricants for incidental food contact is available for compressor, hydraulic, gear and multipurpose applications.
Ultrachem, Inc. (302) 325-9880 www.ultracheminc.com
[email protected] The Torch Is Past (and so are welding and grooving)
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.
Put those welding torches away and pack up that old roll groover, too. Now, there’s a better way to connect stainless steel pipe — with Viega ProPress®. The system is faster, safer and more consistent when compared to traditional methods. Pressing saves labor time and eliminates wasteful downtime. Plus, Viega offers the industry’s widest selection of press fitting sizes (1/2” up to 4”).
Contact Urschel for more information: (219) 464-4811,
[email protected], www.urschel.com
For more information or a demonstration, call 866.766.7805 or visit TheTorchIsPast.com www.foodengineeringmag.com | Food Engineering | November 2011
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CLASSIFIEDMARKETPLACE FOR SALE
The ONLY Company Dedicated to REBUILT Scraped Surface Heat Exchangers s 4RUST ONLY THE OLDEST MOST EXPERIENCED EQUIPMENT REBUILDER s 2ELY ON THE LARGEST INVENTORY IN THE WORLD DOZENS OF MACHINES IN STOCK s #ALL OR EMAIL FOR FREE APPLICATION ENGINEERING AND QUOTES s $ONT WAIT ON ANY MACHINE SHOP TO TRY TO lX YOUR PART GET IT ./7 FROM OUR HUGE INVENTORY OF USED AND PART GET IT ./7 FROM OUR HUGE INVENTORY OF USED AND REBUILT MUTATORS TUBES JACKETS AND MUCH MORE s 3ELL US YOUR SURPLUS EQUIPMENT OR ADVERTISE &2%% ON OUR WEBSITE
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ing Wit 94 6 h Pride Since 1
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Spend more time cooking, less time cleaning. Eliminate packing and allergin contamination. Sanitize quickly and easily. Minimize downtime.
®
SANITARY SPLIT SHAFT SEALS Custom designed and manufactured in Maine by
WOODEX
Bearing Company, Inc.
Georgetown, Maine USA Toll-free (800) 526-8800
http://www.mecoseal.com Worldwide: +1 207 371 2210
EB
R AT
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CEL
Powder & Bulk Engineering Northeast, Somerset NJ 24-25 May 2011 Capper For Sale 2010
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YOUR TRUSTED RESOURCE FOR EQUIPMENT SOLUTIONS FOR 130 YEARS Equipment Sales, Purchases, Rentals & Leasing Auction & Liquidation Services Certi¿ed Market Appraisals Asset Based Loans 130 ACRES FOR 130 YEARS - To learn about Loeb’s carbon offset project and watch our progress in reaching 130 acres of rainforest conservation, visit: WWW.LOEBEQUIPMENT.COM
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EQUIPMENT FOR SALE
N FREEZE WITH EASE O A practical, inexpensive and immediate solution to your cold storage needs. visit us on our web site: www.kellyfreezer.com We Sell Worldwide W Used Carriers in 20 foot and 40 foot sizes R starting at $9,500 E N New BOHN Coolers and Freezers T starting at $10,500 Blast Freezers starting I at $34,500 N G Thinking about Cold Storage?
Phone: 1-866-713-6307 Fax: 1-860-668-2871
Privately owned and operated for over 40 years. Kelly can handle your freezer/ cooler needs from -30 F to 45 F. Ground level, dock height, lighting, walk in doors, insulated roll up doors and most custom features available.
Great Lakes Separators Now Available: Reconditioned ALFA-LAVAL and WESTFALIA Separators Consultants: Dick Lambert, Rick Veneer and Bill Gooderham
Call Dave Lambert (920)863-3306
www.FoodEngineeringMag.com www.foodengineeringmag.com | Food Engineering | November 2011
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EQUIPMENT FOR SALE
MAGNETICS
www.FoodEngineeringMag.com 88
November 2011 | Food Engineering | www.foodengineeringmag.com
FINANCIAL SERVICES
EQUIPMENT FOR SALE
NEED CAPITAL TO GROW?
A PRIVATE EQUITY FIRM INVESTING IN COMPANIES FOCUSED ON CONSUMER PACKAGED GOODS; SPECIFICALLY, BUT NOT LIMITED TO THE FOOD AND BEVERAGE INDUSTRIES
YELLOWSTONE CAPITAL PARTNERS, LLC Houston, Texas
www.FoodEngineeringMag.com
Vreij Kolandjian 1-713-650-0065
[email protected] www.yellowstonecapital.com
AUCTION
Winter Cheese & Dairy Bonanza! Huge On-Line Only Auction Location: Former Star Valley Cheese (Main Facility) 131 Main St., Thayne, WY 83127 Inspection Nov. 8-10. Catalog available early November. * Sale Ends Nov. 18, 2011
Go to www. bidspotter.com for more details! Featured Items: Complete Mozzarella Cheese Plant w/Supreme Cooker-Stretcher, Viking Automated Molder-Chiller, & All S/S Canal Type Brining System, 15-50,000 Gal. Silo Tanks, 40,000 Lb. Double O Cheese Vats, Processors, HTST System, Boilers, Centrifugal & Positive Pumps, Agitated Vessels & Kettles, Late Model Cultured Product Fillers, Antique Dairy Equipment, Late Model Ice Builders & Chilled Water Systems, Butter Churn, Plate & Tubular Heat Exchangers, 1000s of Feet of S/S Tubing, Air & Manual Valves & Much More! Includes: S/S Silo Tanks- 50,3 0, 20 & 15,000 Gallons, Dozens of Add’l 50-7000 Gallon Tanks, Finishing Vats, S/S Roll Stock Machine & Add’l Cheese Packaging & Accessories, Pasta Mfg. Line, Boilers & Electrical, Plant Support, & Complete Waste Treatment System.
Sales Managed by: International Machinery Exchange. For details call (608) 764-5481 or email us at
[email protected] www.foodengineeringmag.com | Food Engineering | November 2011
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EMPLOYMENT
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SERVICES
Wonder Gel Stainless Steel Pickling Gel Achieve maximum corrosion resistance to stainless steel. Surface contamination may drastically reduce the life of stainless steel. Wonder Gel removes (pickles) stubborn impurities, cleans the toughest slag, scale and heat discoloration and restores (passivates) the protective oxide layer. Bradford Derustit Corp. address: 21660 Waterford Dr., Yorba Linda, CA 92887 toll free: 877.899.5315 e-mail:
[email protected]
www.derustit.com AUCTION
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AOLCOM
USED PACKAGING
EQUIPMENT FOR SALE
FLOORING
CALL US WHEN YOU WANT THE JOB DONE RIGHT! IF YOU CAN’T HANDLE A MAJOR RESTORATION PROBLEM, WE ARE HERE TO HELP YOU We also offer do-it-yourself POLY-CHEM kits that allow you to make in-house repairs on spalled concrete, rough expansion joints and areas left around machinery for anchoring. POLY-CHEM is an odorless, one hour cure thus making floor repairs possible without interrupting production.
Ph: 800.669.0438 | Fx: 630.916.0473 www.fortifiedsystems.com SOFTWARE
www.foodengineeringmag.com | Food Engineering | November 2011
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SERVICES
EQUIPMENT FOR SALE
X-RAY INSPECTION Save Your Product And Your Good Name HACCP Compatible solution for detecting foreign particles in your product.
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Call CXR COMPANY • Warsaw, IN 800-817-5763 • fax 574-269-7140 www.cxrcompany.com
FOR SALE/RENT 24 / 7 EMERGENCY SERVICE BOILERS › 20,000-400,000 #/Hr. DIESEL & TURBINE GENERATORS › 50-25,000 KW GEARS & TURBINES › 25-4000 HP WE STOCK LARGE INVENTORIES OF: !IR 0RE (EATERS s %CONOMIZERS s $EAERATORS s 0UMPS s -OTORS s &UEL