Refrigerated & Frozen Foods January 2011

JANUARY 2011 |

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BU S I N E S S AN D TECH NOLOGY SOLUTION S FOR COLD CHAI N PROFE S S IONALS

ON THE FAST TRACK RUIZ FOODS

Supplement to Food Engineering a

Publication

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JANUARY 2011

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VIEWPOINT

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COLD FOOD SAFETY Hot topic Want to get yourself in hot water? Actually, that’s one of several best practices for food plant sanitation.

12 COLD SUPPLY CHAIN & LOGISTICS Rail progress Refrigerated rail investments, innovation address transportation capacity needs – but at a cost.

18 COLD PACKAGING

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Fast food New microwave products address growing demand with better food, packaging technologies.

23 COLD TECHNOLOGY SHOWCASE Showcase on cold plant flooring and suppliers’ other new products for food plants and cold storage warehouses.

32 COVER FEATURE

ON THE FAST TRACK

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On the fast track New packaging, product positioning and brand promotion drive Ruiz Foods’ growth.

40 INSIDE THE PLANT Quick-change artists Quick changeovers, new packaging lines help Ruiz Foods’ Dinuba, Calif., plant meet growth demands.

45 COLD ENERGY MANAGEMENT See the light New cold lighting technologies offer greater energy efficiency, control.

40 REFRIGERATED & FROZEN FOODS (R&FF) REFRIGERATED & FROZEN FOODS is a supplement to FOOD ENGINEERING. REFRIGERATED & FROZEN FOODS is published seven times annually, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Bleuchip International, P.O.Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to REFRIGERATED & FROZEN FOODS, P.O. Box 1080, Skokie, IL 60076. For single copies or back issues: contact Gisele Manelli at (847) 405-4061 or [email protected].

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VIEWPOINT BY BOB GARRISON • [email protected]

VOL. 22, NO. 1

Team Ruiz ne man I’ve known for 20 years. The other, I had known only for about 20 minutes. I was anxious to visit Ruiz Foods in Dinuba, Calif., last fall. It was a chance to reconnect with Chairman Emeritus Fred Ruiz, who was Refrigerated & Frozen Foods’ “Executive of the Year” in 1994. Likewise, I wanted to better know President and CEO Bryce Ruiz, whom I met a decade later – only briefly – when R&FF featured Ruiz as “Processor of the Year” in 2004. That said, I think that Bryce and his sister, Chairman Kim Ruiz Beck, are the first third-generation family company leaders I have known. I wanted to hear all three family members share perspectives on family history and company history. I also was curious for their take on Ruiz Foods’ growth. What used to be a more regional frozen Mexican foods company since has extended its product line, distribution and brand promotion across a national stage. “I don’t exactly know when we became a national company but there is a different dimension now,” Fred admitted. “Bryce is not limited by the past and I think that it’s an advantage. Sometimes the past can be a burden and be limiting in terms of your outlook.” Bryce interjected, “I’ve inherited a sustainable business. I don’t have the burden of asking whether we can simply make payroll and pay the light bill . . . Yet we’re working just as hard and with a sense of urgency. It’s just that we’re taking our time to be more selective and strategic about where and how we push the business.” This, indeed, is a fascinating story on many levels. Ruiz has stepped up its game through…

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PATRICK YOUNG Publisher

… better strategic planning and communication. Like Sandridge Food Corp. (R&FF December), Ruiz dramatically recast its strategic planning and reorganized its people and funding to fewer, bigger, better ideas. … the power of packaging. Ruiz Foods’ retail launch of Tornados and stand-up pouch repackaging (affecting 12 more SKUs) completely overhauled the company’s retail freezercase appeal for customers and consumers alike. … the power of social media. It was none other than Bryce Ruiz, 35, who launched Facebook pages for Ruiz Foods’ brands. In 2010, the two brands registered 2 billion impressions and drove more than 3.5 million brand engagements on Facebook, officials say. Truth be told, Bryce and Kim will face their corporate growth challenges. Even so, it’s great to see this proud family company shifting gears and racing ahead.

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EDITORIAL BOB GARRISON Editor-In-Chief

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PRODUCTION SUZANNE FAIRMAN Production Manager MATT BRITCHER Art Director

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Amy Schuler

Audience Development Coordinator

Carolyn M. Alexander Audience Audit Coordinator

New year, new look Refrigerated & Frozen Foods’ New Year’s resolution is to deliver even more temperaturesensitive insights from thought and technology leaders. We are increasing our coverage of cold food safety and cold food packaging and adding even more muscle to our cold supply chain section with a new executive interview feature. Turn to page 15 to see who’s talking this month. You’ll notice inside, too, that we’ve rearranged magazine departments to complement and surround our cover features. We hope you enjoy R&FF’s new look and contents.

Refrigerated & Frozen Foods JANUARY 2011

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Cold Food Safety

BY BOB GARRISON • [email protected]

Hot topic Photos courtesy Refrigerated Foods Association

Want to get yourself in hot water? Actually, that’s one of several best practices for food plant sanitation.

Expert recommends new non-slip flooring materials and 140ºF washdown water.

lthough food safety already is the group’s perceived strength, the Refrigerated Foods Association (RFA) chose to add even more “meat” to the organization’s upcoming annual spring convention. They invited one of the world’s largest meat processors, Keystone Foods, to provide another perspective on food plant sanitation. Make no mistake. RFA members are no strangers to the rigors of food safety. These are many of the nation’s leading processors of refrigerated prepared entrees, side dishes, soups, salads and desserts. As such, many are quite familiar with the daily handling and processing of raw vegetables and processed meats. Yet even the largest of these companies has just a half-dozen plants or so. On the other hand, Keystone Foods, West Conshohocken, Pa., has 54 plants and distribution centers in 14 countries. RFA’s guest speaker will be Dave Herweyer, Keystone’s corporate global sanitarian. A 37-year professional, Herweyer first worked in Michigan as a public health sanitarian at local and state levels. Later he joined the Sara Lee Corporation’s meat group for 17 years in sanitation, quality assurance and operations. He then served as food safety specialist with two chemical suppliers before joining Keystone Foods. Bill Schwartz is RFA’s technical committee chairman and chief food safety officer for Orval Kent Food Company Inc., a national refrigerated foods processor

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based in Wheeling, Ill. “Food safety is critical to the refrigerated food industry and our meeting draws those individuals who hold food safety at the top of the list of corporate priorities,” he says. “When it comes to producing safe, wholesome food, nothing is more important than having a clean plant and sanitary equipment. That’s why we asked Dave to share his handson, in-the-plant experience from facilities around the world.” Herweyer told Refrigerated & Frozen Foods that he travels extensively to audit Keystone’s meat processing facilities and distribution centers, as well as suppliers’ operations. “We conduct multi-day visits at our facilities to conduct food safety and sanitation audits,” he notes. “And because every plant is different, we look at that facility’s suppliers, ingredients, physical structure, equipment and other areas. “We assist the various teams in our quality assurance, operations, sanitation, engineering and maintenance departments,” he adds. “We’re big on emphasizing continuous improvement.” Understandably, Herweyer also is “big” on food safety and sanitation issues. That’s because the stakes of any food safety incident are so large for consumers and the company itself. “Product recalls and recoveries occur much too often and are challenging to address in the media,” he says. “That’s why

Refrigerated & Frozen Foods JANUARY 2011

we need to remember ‘Murphy’s Law,’ which says that if it can go wrong, there is a good chance it will. It’s important to adhere to Good Manufacturing Practices, industry best practices and all regulations. Sometimes, even the smallest improvements can yield good results.” Herweyer goes on to list just a few small details – such as equipment design, cleaning agents, water and air, and employee development – that he regards as big issues. Equipment: Keystone built and equipped a meat and poultry processing facility in Gadsden, Ala., in 2009. Herweyer notes company officials enjoyed the opportunity to plan and develop every facet of the facility from the concept stage. He along with others from the corporate food safety and engineering teams (as well as operations and management officials from the plants) visited equipment suppliers to ensure that all new machinery would be designed for quick, thorough, and effective sanitation. He suggests that all machinery supports and framework utilize solid or angular steel rather than any hollow tubes where pathogens could grow when stress cracks or other compromises occur. Floors, drains and lighting: Herweyer says many food plants have used anti-slip grating made from plastics and other materials that, ultimately, are too hard to clean. What’s better, he argues, are the continuous types that utilize computer assisted weld points and ‘rough’ stainless steel chips embedded in the surfaces. He recommends AlGrip®, SlipNOT®, DiamondPlate® flooring options with anti-slip enhancements (“replacements that give us both advantages: personnel safety and food safety”). Herweyer notes that Keystone’s Gadsden, Ala., facility also features stateof-the-art facility applications, special floor drains (where individual drain  components may be quickly removed and www.RFFmag.com

Cold Food Safety

Photo courtesy of Food Engineering

water contacts equipment surfaces while retaining effectiveness of the chemicals. Keystone also uses in-plant air handling and circulation systems to quickly dry processing rooms after sanitation. Micro levels are less in dry environments.

Invest in people

Keystone Foods’ Gadsden, Ala., plant uses recessed, flooded foot baths to ensure optimal sanitation.

sanitized), lighting fixtures compatible with daily wash-downs and designated storage locations for machine components during sanitation and maintenance. Cleaning agents: Cleaning chemicals are a significant sanitation cost – second only to labor and in many cases, ahead of energy. Herweyer suggests that too many processors treat chemicals like commodities and simply choose to buy on price. “I don’t subscribe to that,” he says. “Although we’ve mandated some standards, we also like to work cooperatively and utilize the expertise of our suppliers; things that may be missed if looking only at cost instead of value. We bring suppliers in on a pre-determined frequency as an extra set of eyes for problem solving or suggestions for challenging applications.” Herweyer says there are varying levels of quality and effectiveness of commercial cleaners and the least-cost product may not be the most effective nor least-cost cleaning option in the long term. He notes, for example, that the most effective smokehouse cleaners often achieve that status due to the presence of a good rinse www.RFFmag.com

agent which adds to the initial cost but provides value when considering the cost of extra labor involved in overcoming the problems associated with less expensive formulations. Another example of a more complex formulation adding value? Herweyer says the foaming application of sanitizers can help reduce the micro soil loads in most plants. Moreover, these applications are better because they allow greater contact time especially on vertical surfaces. Water, air: Herweyer says water often represents a “pitfall” area for many food plant sanitation programs. “Very frequently, adequate hot water is not available for the entire cleaning shift,” he notes. Herweyer recommends that plants maintain water temperature requirement of central rinse systems at 140°F minimum. The physical and chemical reactions during the application of commercial cleaners and degreasers are more effective at this level. Combined with adequate volume, this temperature allows for the decrease in temperature when the

Great sanitation products and practices aren’t worth mentioning … without people, says Herweyer. Thus, he turns any conversation away from sloped metal angles – toward the human resources angle. “It’s rare to find sanitation people with 10 to 15 years experience. The rewards are more enticing in other fields and many leave,” he says. “We have to say ‘enough’s enough’ and do more to keep good people. Right now, you either have to ‘build’ or ‘buy’ a good sanitarian. “The food processing industry is challenged with higher than desirable turnover in this area,” he adds. “Yet, we’ve decided to try to do more in selecting and training employees to retain them. We treat it like an entry-level career position. We think of the people that run our cleaning crews as an essential part of plant management . . . and it goes a long way when management spends time with a crew. There’s nothing better than a pat on the back and any time an official spends time with the sanitation crew, it’s worth it.” It’s here that Herweyer draws an important conclusion. “In my role, I look at equipment very carefully. Then again, if you don’t provide the time, tools and talent to your maintenance and sanitation people – you put your company at an avoidable risk. Smaller companies may not have the same resources but it’s still a matter of focus on these priorities that is a proven winner.”

Refrigerated & Frozen Foods JANUARY 2011 9

Put the freeze on rising operational costs. Costly top-ups. Downtime caused by deposits. Clogged filters. They can all hurt your bottom line. That’s why choosing the right compressor fluid is so important. Petro-Canada’s comprehensive line of REFLO™ A compressor fluids can save you money and reduce fluid consumption. Talk to a representative about our Tangible Savings Solutions and compare your current fluid choice with the REFLO product that is right for you. And put rising operational costs on ice.

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Tangible and reliable savings “We are so impressed with REFLO 68A that we will be undertaking a complete changeover.” – Richard Garstman Contrary to popular belief, there are parts of The Netherlands that are extremely cold year-round. For instance, there’s a place in Vlissingen that’s known for its continual chilly conditions – it’s called Kloosterboer, one of the largest facilities for chilling and freezing in the country. Founded in 1925, Kloosterboer started out as a vegetable trader. Throughout the years several services have been added and enhanced. The company is now recognized as one of the industry’s best. The Vlissingen Facility With a cold storage capacity of 155,000 tons, the facility located in Vlissingen is Kloosterboer’s largest. Situated on its own quay, the facility employs over 200 people and houses cutting edge technologies and optimized logistics. The cold storage space in the plant is cooled with Grasso refrigeration compressors. The only time the compressors are shut down is

during service intervals and repairs. Though maintenance and repairs are inevitable, Richard Garstman, the facility’s Cooling Technology Engineer, works hard to limit and lessen downtime occurrences. He knows that the right maintenance protocol combined with the application of proper lubricants can help to reduce unnecessary downtime. Fluid Consumption Was High Garstman consulted with his lubricant supplier, KLT; they told him about a product manufactured by Petro-Canada called REFLO 68A and also provided him with testimonials from current REFLO users as well as Grasso trial recommendations and approvals. Why REFLO 68A Was Recommended KLT recommended REFLO 68A because it’s an ammonia refrigeration compressor fluid used in industrial refrigeration systems – one that is formulated to outperform solvent refined paraffinic and naphthenic refrigerant oils.

The Switch Three Grasso screw compressors in the Vlissingen facility were switched to REFLO 68A. The results have been very favorable, especially with fluid consumption as it has been reduced. “Our fluid consumption has decreased by 60%!” REFLO 68A’s lower oil volatility can help reduce the oil carry-over seen with solvent refined paraffinic and naphthenic fluids. Lower oil carry-over improves refrigerant flow and can cut fluid consumption.* The Full Changeover REFLO 68A has performed so well in the Vlissingen facility that Kloosterboer has switched all compressors in the other Vlissingen locations to the lubricant. “We are so impressed with REFLO 68A that we will be undertaking a complete changeover,” says Garstman. “Next up are 3 Grasso RC piston compressors at our facility in Denemarken.”

Massive Chilling And Freeze Storage Facility Reduces Fluid Consumption After Switch To REFLO 68A. After a very successful trial, Kloosterboer’s Vlissingen facility is planning to convert all of their Grasso refrigeration compressors over to REFLO 68A. Shown to the left is one of the Grasso refrigeration compressors in the Vlissingen facility.

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Cold Supply Chain & Logistics BY GREG SARGIS

Rail progress

Photo courtesy of Rail Logistics LLC

Refrigerated rail investments, innovation address transportation capacity needs – but at a cost.

New double-stack container service provides shipping between Washington state and Chicago.

t’s no secret that refrigerated and frozen transportation is a dynamic, commoditized market. In fact, the only predictable market factors are the peaks and valleys in rates and capacity. Throughout these boom, bust, revenue and demand cycles, refrigerated shipping has absorbed driver shortages, fuel increases, regulation and legislation. Still, it remains one of the world’s most competitive markets. Refrigerated truck and rail have been shippers’ two main long-haul options (in excess of 1,500 miles). Interestingly, there now are more variations than ever before within these two basic modes. There are multiple sizes of private and railroad-owned boxcars in manifest (mixed railcar) trains, dedicated unit trains (one type of railcar from one origin to one destination) and trailer-on-a-flat-car (TOFC) intermodal. For the first time in years, shippers also have a choice involving domestic intermodal refrigerated containers (COFC). Each option presents unique operational, financial and service characteristics. Here’s a review.

I

Boxcar Manifest Service (two-truckload to four-truckload capacity railcars) Large, bulk volume refrigerated and frozen food shippers use this form of manifest train, which can include multiple car types (either owned by private companies or the railroads). This network relies on boxcar rail-served facilities at each end. 12

Refrigerated & Frozen Foods JANUARY 2011

On-time is typically with a week of published transit time. Savings (depending on incremental storage and handling cost calculations) are between $.01 to $.02 per pound or $400 to $800 per truck. With one transload added, a shipper or consignee can quickly erode any savings versus truck. Again, shippers best suited for this service are those with relatively dense, stackable, large volume loads containing a low total number of SKUs. Small shippers have very limited access to large railcars. Product tends to be floor loaded or slip sheeted on and off the railcars. Crushing can be a challenge with the larger interior heights exceeding 11 feet. The Union Pacific Railroad has the largest number of refrigerated railcars and the largest market share. It offers shippers a West Coast “Express Lane” program with 10-day service to the Northeast.

Boxcar Unit train This offering features large-capacity railcars (three to four truckloads) with transit times approximating single-driver service. The Union Pacific offers two of these trains through Railex. These coast-to-coast trains run two days per week of scheduled service from the Pacific Northwest and Southern California to Upstate New York in a five-day period. Each train has the capacity to transport the equivalent of 1,120 trucks of perishable product in each direction. These trains provide speed, consistent capacity and forward position of inventory or door-to-door delivery at a sav ings to truck. Although capacity and service are excellent www.RFFmag.com

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Cold Supply Chain & Logistics

Trucking company debuts TempStack, a 53’ refrigerated container-on-flatcar offering.

throughout the year, one drawback is that this model includes multiple handles on the freight.

Refrigerated intermodal Shippers now have two options: a trailer on a flat car (TOFC) or the recent addition of double-stack refrigerated containers on a well car (COFC). Intermodal is an excellent substitute for single-driver truck service between the West, East and Midwest. Payload and transit time is approximately equal to truck and priced at a savings of $.005 per pound, or $200 or greater per truckload. The BNSF railroad was an early market innovator here and continues to be the market’s largest rail provider of refrigerated intermodal services. Almost all large refrigerated trucking companies offer intermodal services to complement their highway divisions. The largest refrigerated intermodal carrier in TOFC is Alliance Shippers with more than 1,600 intermodal trailers. As mentioned, the newest market development involves domestic refrigerated intermodal double-stack containers. This service offers the additional efficiency of double-stack rail transit density and is 14

projected to provide savings over TOFC but not boxcar. We are beginning to see new service offerings using these containers. One such example is the dedicated refrigerated double-stack container train that BNSF offers through Rail Logistics LLC. This network operates from the state of Washington to Chicago (and back) and it is adding critical capacity between major markets. Several large refrigerated intermodal carriers are exploring this new mode or already have committed to adding containers to their fleet. The nation’s largest refrigerated carrier (C.R. England), has committed to 300 containers to be delivered within the year. Observers project that the domestic refrigerated container market will grow from near zero in 2010 to more than 1,000 units by the end of 2011. Some challenges here may include chassis management, weight and cube payload maximization versus lower weight trailers.

Market maneuvers In the recent past – when there were only two or three truck/rail options – the value or savings gap between boxcar rail and highway truck was significant, ($.02

Refrigerated & Frozen Foods JANUARY 2011

to $.03 per pound or $800 to $1,200 per truckload). Today, however, that gap has narrowed. Regulations and fuel prices have increased truck costs. Even so, costs likewise are rising in the more efficient rail mode. The biggest change in rail’s value proposition is that it’s more difficult to identify cost or value differences between truck and rail. In some cases, rail options either match or exceed available truck rates. And although truck costs remain largely transparent, it is more difficult to pinpoint “cost drivers” behind rising rail prices. That said, rail offers critical consistent service and supply in a tight capacity market. And of course, when capacity is a problem, rates ultimately rank a distant second to perishable transportation supply. We’re entering a critical time period. Driver and operating regulations, operating costs and capital constraints are reducing truck capacity. Meanwhile, environmental measures and engine requirements are pushing most late-model trucks and refrigerated trailers into the secondary market. There are still more variables as larger carriers choosing not to manage a California-only fleet. In turn, they are upgrading all other assets. Elsewhere, smaller carriers may not be able to invest or command the rates needed to support new investments. Refrigerated rail equipment and technology investments and innovation are adding critical capacity to shippers and receivers. We expect to see rail options fill the capacity void. However, as rates inch upward, it will only blur the cost and value differences between these modal options. Greg Sargis is president of LOGO Carriers and Gem State Logistics, a Boise, Idaho, agency of TTS, LLC. A 25-year food industry supply chain veteran, Sargis has held senior logistics posts with Nestlé USA, Nabisco and Simplot Food Group. Readers may call (866) 443-4147 or reach him at [email protected]. www.RFFmag.com

Cold Supply Chain & Logistics

Executive insights Birds Eye view of logistics Refrigerated & Frozen Foods talks with Mike Nardella, vice president of logistics for Pinnacle Foods Group LLC. Pinnacle is the Mountain Lakes, N.J., parent to such frozen food brands as Birds Eye®, Aunt Jemima®, Mrs. Paul’s®, Van de Kamp’s®, Swanson Hungry-Man®, Celeste® and Lender’s®. R&FF: Pinnacle is a large, diversified company. How is your job structured? Mike Nardella: Shortly after the (December 2009) acquisition of Birds Eye Foods, Pinnacle Foods Group reorganized into three business units: the Duncan Hines Grocery Division, the Birds Eye Frozen Division, and the Specialty Foods Division. Logistics is part of a shared services group. Our team interacts with each separate business unit in both a tactical as well as strategic function. Since my team is broken down into a dry (which also services the Specialty unit) and frozen group, we are able to address the specific needs of each group. R&FF: What were your biggest challenges and successes in calendar 2010? Nardella: Our biggest challenge was to integrate the Birds Eye business within our logistics network in just under six months. We structured logistics for efficiency and moved some logistics functions in house. Although this was a difficult task, it also proved to be our biggest success. We executed the transition with a great deal of precision and accuracy. In addition, we were able to achieve all of our planned synergies. R&FF: What were your Birds Eye objectives during the second half of last year? Nardella: Once the integration was complete, we wanted to better understand this new business. This, in itself, was a challenge. We were in our [vegetable] growing season and the harvest was starting to come in. We needed to anticipate and plan for overflow bulk storage warehouses. Today, we still feel as though there are many aspects of the business we need to work through. That will include our logistics footprint. R&FF: What industry issues give you the most cause for concern? Why? Nardella: There are a few areas that get my attention. These are issues such as truck and driver capacity, effects of the CSA 2010 regulation, EOBR (electronic logs), new safety regulations and rising fuel costs. All these issues and developments appear to present a “perfect storm” for carriers. R&FF: What are a few frozen warehousing goals for calendar 2011? www.RFFmag.com

MEET MIKE NARDELLA Background: Nardella has more than 35 years of transportation and logistics at corporate and third-party companies. He co-founded an on-line returns business and has held various senior level supply chain posts at M&M/Mars, Johnson and Johnson, Playtex, Genco Logistics and Avon Products. Education: B.S. Business Logistics; MBA, Penn State University FYI: Nardella holds two patents related to bulk material handling systems and returns processing. He has held logistics association program and conference chair positions and served on executive boards overseeing the Warehousing Education Research Council and Council of Supply Chain Management Professionals. Nardella: We believe flexibility and speed at the docks will be very important. One goal will be to ensure that we gain additional flexibility to accommodate drivers upon arrival. R&FF: How about a few frozen transportation goals? Nardella: There will be several frozen warehouse initiatives. In conjunction, however, we do need to work with our base of frozen carriers. We want to maximize efficiencies by reducing empty miles and better accommodating drivers at loading docks. R&FF: What will be the frozen food industry’s most critical logistics challenge in calendar 2011? Nardella: I think we’re just seeing the tip of the iceberg with respect to transportation regulations. Although we can anticipate some of the effects of regulations: new safety requirements, rising fuel costs, driver shortages, etc; we cannot project the real impact. We know one thing. Whatever happens will shape the logistics frontier and the competitive supply chain environment. Those companies competing for capacity must develop creative solutions and strategic partnerships. I also see more manufacturers collaborating in areas of planning and operations to create win-win situations for both carriers and manufacturing. R&FF: Now a lighter question. What Pinnacle product is in your home freezer? Nardella: Of all our frozen products, I particularly enjoy Birds Eye Voila! Garlic Chicken. It is as good as an entrée from a restaurant and offers a hearty portion. I’d encourage everyone to try it. Refrigerated & Frozen Foods JANUARY 2011 15

Odenberg Pallet-Link® System

Booth 4639

DSI Adaptive Slicer™

Double D Searer/Grill Marker

More innovations for poultry processors at IPE. Just what you would expect from JBT FoodTech. As a longtime provider of integrated processing solutions for poultry processors, JBT FoodTech continues to enhance its capabilities: …
The new DSI Adaptive Slicer™ system combines with the DSI Waterjet Portioning system to create a DSI Adaptive 3D Portioning™ System allowing for double-digit yield improvement. …
For enhanced product appearance, JBT FoodTech also now offers the Double D Searer/Grill Marker suitable for a variety of poultry applications. …
For processing efficiency and value, JBT FoodTech has unveiled the MX-II, a next generation MicroMAX™ Filter. …
Most recently JBT FoodTech has been named the exclusive sales agent in North America for the Odenberg Pallet-Link® System. The Odenberg Pallet-Link system offers variable retention time and buffering for controlled parameter chilling and freezing for multiple products at one time.

We’re with you, right down the line.™ www.jbtfoodtech.com Booth 4639

K L

A H

C LKSE A P T T I 4639 A

BO

H T O

Hear what the experts have to say about the latest technologies in portioning, slicing, coating, frying, cooking, freezing and maintenance. It’s all happening at booth 4639. Stop in. Our best minds will be there to field any and all questions. Interested in automated portioning and slicing? See what’s new with our DSI technologies. High volume cooking on your hit list? Learn about the latest Stein MultiPhase™ cooking solutions and the new Double D searer/grill marker. Freezing? We’ve got Frigoscandia and Northfield solutions. Aftermarket Parts and Service? Speak with one of our specialists at the Aftermarket counter. We know you have a lot of ground to cover at IPE so we’ll get to the point and get you on your way.

JBT FoodTech is now the exclusive North American sales agent for the Odenberg Pallet-Link® system. The patented Pallet-Link system provides controlled parameter chilling and freezing for multiple products, simultaneously.

We’re with you, right down the line.™ www.jbtfoodtech.com Booth 4639

Cold Packaging Solutions BY BOB GARRISON • [email protected]

Fast food New products feature better food, packaging technology for growing consumer demand. t’s not a chicken-or-the-egg question of which came first. Refrigerated and frozen prepared foods predate microwaves. Yet prepared foods and microwave packaging now enjoy a closer, symbiotic relationship. In fact, microwave meals grabbed the headlines in The NPD Group’s “24th Annual Report on Eating Patterns in America” report in late 2009. The Chicago researcher noted that although Americans are eating at home more – and have been since the beginning of the decade – 2008 marked a turning point as more households prepared their foods in microwaves. “Microwaving has been flat for two decades, but it increased (in 2008) as Americans found a way to eat at home and not cook,” said Harry Balzer, NPD’s chief food and beverage industry analyst and study author. “We’re using our microwaves to warm and heat more – but not prepare more dishes from scratch.” NPD said Americans used their microwave ovens more and their stove tops less

I

PERCENT OF MAIN MEALS USING MICROWAVE 19.7

20.0

19.8

22.5

20.5

10.5

Technology aids trend

1985 1990 1995 2000 2005 2009

Source: The NPD Group/ National Eating Trends

18

in 2008. Approximately 20 percent of all meals prepared in U.S. homes from 1990 to 2007 involved the use of a microwave, until 2008, when usage rose ten percent. Balzer said stove tops remain the most popular cooking appliance but the percent of main meals prepared on a stove top dropped from 52 percent in 1985 to 33 percent in 2009. “There was a lot of speculation last year as to how our eating behaviors changed as a result of the economic crisis. The truth is that consumer behavior changes slowly,” says Balzer. “I’ve observed America’s eating patterns in good and bad economies, and the constant is that there is no recession in eating and Americans don’t want to cook what they eat.” Approaching the trend from a different angle was The Freedonia Group. This Cleveland researcher projects U.S. frozen food packaging demand will climb 3.7 percent each year through 2013. Officials estimate the market at $5.7 billion in annual sales and say their research factors industry data from 1998, 2008 and 2008. “Gains will be driven by the popularity of convenience-type foods, the prevalence of microwave ovens, and technological advances in packaging,” said Freedonia. “Frozen food specialties and meat, poultry and seafood will be the fastest growing applications.”

How is microwave packaging technology keeping up with consumer demand for quick, convenient food? Refrigerated & Frozen Foods put that question to Tim Bohrer, a 30-year plus packaging industry veteran and founder of Pac Advantage Consulting LLC, Chicago. Bohrer says it’s common to have “surges” of patent applications and technical development activity, followed by

Refrigerated & Frozen Foods JANUARY 2011

Steaming meets the stand-up pouch.

surges of product commercialization. “There are industry lulls but then things pick up when you have developments in both food formulation and packaging technology,” he says. “It comes down to having products that consumers want to be able to handle more conveniently and when these developments come together, it spurs the next fad or next generation of microwaveable products. “There’s give-and-take between food technology and microwave packaging,” he says. “Some of these technologies have been around for awhile. Yet we’ve seen a resurgence in frozen foods, particularly as companies improve the quality of their ingredients.” Bohrer gives a thumbs up to new Marie Callender’s Multi-Serve Bakes (from ConAgra Foods), which involves microwave shielding and field modification materials that evenly heat the entrée so consumers don’t even have to stop and stir. Bohrer says he also addressed the International Microwave Power Institute’s recent technical symposium and cited two susceptor-based applications for frozen deep-dish pizza. Bohrer noted that each offering – from Gino’s East and DiGiorno (Nestle Pizza) – successfully used different approaches to heat the deep-dish pizza and deliver a crisp crust. Elsewhere, Bohrer says microwave www.RFFmag.com

S U C C E S S

S T O R I E S

HOW A VEMAG SLICE DEPOSITOR

eliminated HAND -L AB O R a n d i n c r ea sed SANDWIC H SAL E S A TRUE STORY: A sandwich maker came to Reiser at a tradeshow lamenting how much labor was required to make a simple peanut butter and jelly sandwich for commissaries and vending machines. The problem was that the peanut butter needed to be spread onto both slices of bread to prevent the jelly from leaking through and “staining” the bread. Reiser put its engineers to work and they developed the Vemag Slice Depositor. This system automatically deposits a clean, even, exact-weight covering of peanut butter directly onto the bread. Now making sandwiches was a snap. The customer then determined that the same technology could be applied to cheese slices, and then tuna salad, chicken salad and other sandwich fillngs. The sandwich maker’s sales took off and Reiser had earned another customer’s loyalty.

THE VEMAG QUICKLY & EASILY PRODUCES PERFECT SANDWICHES Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

Leading the food industry in processing and packaging solutions.

Cold Packaging Solutions

News & notes Schwan’s taps chef, microwave bag for new line They say two heads are better than one. That’s why Schwan’s Home Service, Marshall, Minn., says it hired award-winning, nationally recognized chef Jet Tila, to create a new line of Asian-inspired meals for Schwan’s home delivery business. In doing so, Schwan’s also turned to Amazing Food Creations! LLC, a Schaumburg, Ill., company that’s patented a Steamazing! microwaveable brown paper pouch for its own entrees – as well as for contract and private label customers. Amazing Food Creations’ founder and chef Eric Carre says the steam-based system combines sous vide vacuum cooking and microwave popcorn bag technologies. New technology for optimum microwaving General Mills, Pinnacle Foods and Heinz North America are among those frozen food processors licensing a new technology developed by Microwave Science JV LLC, Los Angeles. Available on select Kenmore or LG microwaves, new TrueCookPlus is a two-part system. First, it uses software installed onto the microwave ovens by the manufacturer. Officials say the software accounts for cook time variables such as oven temperature, wattage, oven size, voltage, power settings and even location altitude. The second part involves short, simple TrueCookPlus numeric codes that appear on package fronts. Consumers simply press the microwave’s TrueCookPlus button, enter the related product package code and then press “start.” steaming now has proliferated with many executions across as many as six distinct film-venting technologies. These range from older, traditional applications requiring the consumer to manually cut a pouch – all the way to valves and and pressure-release materials the use laser scoring. Meanwhile, Bohrer says new microwave steaming applications have branched into (1) stand-up pouch entrees, (2) a broader number of private label offerings and (3) upscale premium seafood applications.

What’s next? Asked about near-term developments, Bohrer says there’s more in store. “We’ll see a continued market expansion. There’s been a burst of activity involving both susceptor and steam packaging and we’ll see even more use of these technologies in 2011,” he says. “The Marie Callender’s product, in particular, will have a ‘halo’ effect and bode well for other premium, high-quality foods. That product formulation and package delivers nice temperature distribution that mimics the oven and results in a superior product in less time (than a conventional oven).” With another reference to seafood, Bohrer says industry groups no doubt will debate the best packaging and labeling of raw products intended for microwave use. 20

Refrigerated & Frozen Foods JANUARY 2011

Bohrer also points to several opportunities for processors. These include … … new technologies for breaded, high-moisture products. Maybe the world doesn’t need another chicken nugget – but it could certainly use a better one, says Bohrer. It’s tricky to heat a whole-muscle product so that the breaded outside remains crispy while the inside retains its moisture. A successful product and package would appeal to kids and spur broader applications. … a single package with both susceptor and steam technologies. Bohrer describes Nestle Prepared Foods’ new (Stouffer’s) soup-and-sandwich offering as interesting because it combines various foods and packages with different heating technologies. He says the next “breakthrough” will involve a multi-component meal with where packaging (with shielding) automatically handles food components that need both steaming and/or crisping. … communicating a green message. Bohrer says food processors can tout a green, sustainability angle with microwavable foods. Industry and supplier researchers already have studied household appliance energy use and projected that microwaves use as much as 80 percent less energy than a conventional oven. Researchers even have studied microwave energy use between trays with susceptors (which can cook to desired characteristics faster) and trays without susceptors. Their objective: show that susceptor packs require less microwave energy and achieve superior cooking results. www.RFFmag.com

FREE

Webinar

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How to Choose the Best Accumulation Solution for your Application Thursday, January 20, 2011 | 2:00 – 3:00 p.m. EST With so many accumulation equipment options available, how do you make the right choice for your packaging line? In this webinar, we will provide a side-by-side comparison of all the accumulators commonly used in the packaging industry today. • Learn best practices for each machine, including types of products, floor space and accumulation time required for the application • Learn the operating pitfalls for each type of accumulator

SPEAKERS

Jim Streblow V.P. Sales and Marketing Nercon Eng. & Mfg., Inc.

• Learn the buffering and controls capabilities of each accumulator • Learn about purchase cost and life cycle cost for each accumulation solution • See a decision matrix demonstration on choosing the right accumulation solution

webinar.foodengineeringmag.com Can’t attend live? Register and watch on-demand.

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Mike Weickert Director of Applications Engineering Nercon Eng. & Mfg., Inc.

Cold Technology Showcase FOCUS ON: COLD FACILITY FLOORING Better floor, more uptime Fricks’ FSC Advantage™ shrinkage compensating concrete floors provide durability for more uptime with less facility maintenance and equipment maintenance. Facility operators can eliminate as much as 90 percent of floor joints by using Fricks’ FSC Advantage™ shrinkage compensating concrete floors. These light-reflective concrete floors feature steel edge armored joints, traprock floor hardener and Rebar reinforced construction. Fricks’ FSC Advantage™ shrinkage compensating concrete floors won’t curl and sealers are not required. – The Fricks Company (817) 560-8281 / www.thefrickscompany.com

Floor problems? Call us. We do more than create long-lasting, great looking floors. Stonhard has more than 350 project engineers and 200 specially trained installation crews to precise food industry solutions. From custom designs and project support to proven performance and comprehensive service, we solve your toughest flooring problems. Moreover, Stonhard has proven experience with bakeries, dairies, rendering and meat packing, packaging rooms, coolers, splash/spill zones, mixing areas and more. Our chemical-, impact- and abrasion-resistant floors also are sanitary, safe and easy to clean. – Stonhard (800) 257-7953 / www.stonhard.com 

An ERGONOMIC solution that safely & securely transfers product in single & multiple layers from one pallet to another. Applications include: Order fulfillment, specializing in bulk delivery. Creation of mixed pallets & pallet transfer. Conveyor feeding. Breakdown of damaged pallets. Breakdown of incoming product for receiving. Increase pick rates from 200 cases per hour manually to over 2,000 cases per hour with The TYGARD CLAW. An investment that provides a wide array of benefits, including major savings through reductions in manual labor, seasonal employment, overtime, warehouse injuries & overall insurance costs. The industry leader with over 15 years of proven results.

Products & Features Include: • The high performance Tygard Claw Side Mounted Systems. • The versatile quick disconnect Front Mounted Tygard Claw. • Tygard’s layer pick technology easily handles product no other attachment can. Including multiple sized pallets with ranges from 32”x37” to 40” x 48”.

www.RFFmag.com

Phone: ( 7 2 4 ) 7 4 6 - 4 5 0 0 To l l F re e : 1 - 8 7 7 - 7 4 6 - 4 5 0 1 e m a i l : i n f o @ t y g a r d c l aw. c o m v i s i t : www.tygardclaw.com 300 Meadowlands Blvd • Washington, PA 15301

Refrigerated & Frozen Foods JANUARY 2011 23

Cold Technology Showcase Get more from your floor Want to boost handling speed, reduce lift truck maintenance and become more environmentally sound? Kalman floors use 80 percent fewer joints and 33 percent less rebar. We deliver the industry’s highest quality cold storage floor because our customers demand floors that require minimal maintenance under extreme operating conditions. Our self–polishing, abrasion resistant warehouse floor withstands high traffic volume and temperature extremes with minimal cracking to avoid costly shutdowns and slowed material handling speeds. Ask us about floor repair at working temperature! – Kalman Floor Company 800-525-7840 / www.kalmanfloor.com

We know food flooring Atlas VTF Systems use vitrified tile in a direct bond flooring system to combine optimal aesthetics, uniformity and durability and chemical resistance. VTF system floors resist most food processing materials, by-products and residues as they exist; or the changed chemical or biological state they acquire, such as fermented sugars or alcohols. Atlas VTF resists cleaning agents, detergents, soaps as well as fats, oils, greases, solvents, salts and acids used in food processing areas or the equipment sanitation and maintenance. Our system includes VTF tile, setting bed and specialized grouts. – Atlas Minerals & Chemicals Inc. (800) 523-8269 / www.atlasvtfsystem.com 

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

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Refrigerated & Frozen Foods JANUARY 2011

www.RFFmag.com

Cold Technology Showcase

Don’t worry. It’s tough enough.

Stronger, easier to clean

Rust-Oleum’s ThermaKrete® Urethane Concrete Coating is designed for the extreme conditions of food, beverage, meat processing and cold storage environments. ThermaKrete seamlessly expands and contracts to resist cracking. Available in 3/16” or 1/4”, this thick flooring armor shields against thermal shock with temperature fluctuations from -10ºF to 240ºF. ThermaKrete withstands caustic washdowns, heavy traffic, high impact, abrasion, chemicals and standing water contamination. – RustOleum Corporation 800-769-6565 / www.rustoleum.com

Ashworth’s new Omni-Pro® conveyor belts feature patented Zero-Tension, 360˚ Buttonless Welds, which are stronger and easier to clean than conventional bridge-welded belts. By eliminating traditional bridge welding with the Zero-Tension 360˚ Buttonless Weld, all Omni-Pro® belts can withstand the highest loads in their class. Unlike a traditional bridge weld, the Zero-Tension 360˚ Buttonless Weld is free from surface imperfections and crevices, eliminating bacteria entrapments and improving cleaning characteristics. – Ashworth Bros. Inc. (800) 682-4594 / www.ashworth.com

Hygienic design, easy access EVAPCO introduces small and medium SSTMC unit coolers for freezers, coolers and docks requiring low, medium and high temp applications. SSTMC models offer improved accessibility features, clean cabinet/pan design and corrosion inhibiting materials of construction. SSTMC evaporators have stainless steel tube/aluminum fin with a new hygienic cabinet design. This product includes Low Energy (-LE) and Lower Sound (-LS) models. SSTMC evaporators come in capacities from 1.5 to 56 TR. These feature axial fans and many user-oriented features such as sloped top panels, hinged fan panels and dual sloped full coverage drain pans. – EVAPCO Inc. (410) 756-2600 / www.evapco.com

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Refrigerated & Frozen Foods JANUARY 2011

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Cold Technology Showcase Smarter lighting choice

Eliminate ice, frost Munters’ IceDry® unit reduces and/ or prevents ice and frost build up in cold storage areas. In fact, we’ve designed it especially for installation inside cold storage and process freezers where temperatures reach as low as -30°F. Ice Dry will begin to remove ice immediately and can automatically adjust to keep ice build-up – due to moisture infiltration – under control. This helps ensure reliable and energy efficient operation. – Munters Corp. 800-843-5360 / www.munters.us

Lumetric’s SmartPOD is the only true lighting option for large refrigerated areas. The extraordinarily efficient SmartPOD generates no heat, provides superior light quality and delivers up to 90 percent energy savings with intelligent control, continual dimming and demand response. Costly LED products can’t hold a footcandle to the SmartPOD in terms of lumens/ watt, which means they can only deliver a slice of the light Lumetric can. LEDs have their place but just not in your large area work spaces. – Lumetric (510) 668-0600 / www.lumetric.com

Self calibrating, Title 21 compliant

Designed to conform to traceable event recording guidelines under FDA Title 21, Heat and Control’s new CEIA THS 21e metal detector continuously tests and calibrates itself for peak performance. Single- and three-frequency models feature a new electronic platform for superior stability. CEIA THS 21e also features a stainless steel casing, keyboard and conformal coated circuit boards for IP65K washdown. New software packages also allow remote programming and data management. – Heat and Control Inc. 800 227 5980 / www.heatandcontrol.com

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Refrigerated & Frozen Foods JANUARY 2011

RFF04094FRIC.indd 1

www.RFFmag.com 3/24/09 3:20:20 PM

Call Request Foods for 2011 copacking programs in our new, state-of-the-art production facility You’ve known Request Foods for copacking single serve and family style frozen entrees and side dishes. Now, you can have Request Foods’ culinary excellence in your skillet meals, too. Our state-ofthe-art facility will be online June, 2011, with scalable capacity for your private or national brand meal kits. From fresh ideas to freezer case leadership, Request Foods is your skillet meal copacking partner.

3460 John F. Donnelly Dr., Holland, Michigan 49424 ÊȣȰÇnÈ°ä™ääÊÊÊÊUÊÊÊÊÀiµÕiÃÌvœœ`ðVœ“

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

W Sunday, April 3 12:30 p.m.

Golf Tournament 3:00 – 5:30 p.m.

Registration 7:00 – 8:30 p.m.

Welcome Reception

9:15 – 10:00 a.m.

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

Project Economics: Selling Plant Automation Improvements

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

Registration 7:00 – 8:00 a.m.

Continental Breakfast

Moderator: Christopher Miller, Food Industry Consultant and Founder & CEO, Innovation Focus In this interactive session, audience members will collaborate on project cost analysis and economic justifications for undertaking plant automation capital investments. Join your peers as they create best practices and recommendations for gaining approval on critical plant improvement projects.

8:00 – 8:10 a.m.

Welcome Patrick Young, Publisher, Food Engineering

12:00 – 1:30

Expo and Lunch

8:10 – 8:30 a.m.

12:00 – 4:00 p.m.

Opening Remarks: The State of Food Manufacturing

Expo

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

Theme for Day One: Continuous Improvement in Challenging Times

Solutions Theater

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

Keynote Address: The Road to Manufacturing Innovation Keynote Speaker: Carlos del Sol, Vice President, Global Engineering Systems, Campbell Soup Company All food and beverage processors are searching for innovative practices to gain a competitive edge. In a constantly changing and challenging manufacturing environment, the speaker will address globalization, operational efficiency and the need for better management of both human and equipment assets.

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

Tuesday, April 5th Track A 9:00-9:30 a.m.  Siemens Industry, Inc. 9:30-10:00 a.m.  Solarsoft Business Systems Track B 9:00-9:30 a.m.  Adept Technology

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2:00 to 2:30 p.m.

3:00 to 3:45 p.m.

Refreshment Break Stations

Sanitary Design of Equipment: What You Should Know

5:00 – 6:00 p.m.

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

Expo Reception 6:00 – 8:00 p.m.

Palm Beach Dinner

W Tuesday, April 5

3:45 to 4:30 p.m.

Plant of the Year Award

7:30 a.m. – 1:00 p.m.

Registration

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

7:30 – 8:30 a.m.

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

Plant of the Year Celebration Cocktail Reception

8:00 – 10:00 a.m.

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

Educational Tracks on State-of-the-Art Methodologies

W Wednesday, April 6 Monkeiwicz

Palczewski

Kovach

Zelusky

Jeffries

Posada

SESSION A: PACKAGING TECHNOLOGY 10:30 a.m. Implementing a Successful Robotics System Speaker: Peter Monkeiwicz, VP of Operations, Kayem Foods Inc. 11:00 a.m. Case Study: New Packaging Materials Implementation Project Speaker: Bob Palczewski, Engineering Director, Celebration Foods 11:30 a.m. Changing the World Through Lean Six Sigma Speaker: Tina Kovach, Continuous Improvement Manager, Dawn Foods SESSION B: PROCESSING TECHNOLOGY 10:30 a.m. Metal Detection/X-Ray Speaker: Paul Zelusky, Manager of Quality Assurance, The Hershey Company 11:00 a.m. Combustible Dust and Plant Safety Speaker: Kevin Jeffries, Corporate Safety Systems Manager, Imperial Sugar 11:30 a.m. Clean-in-Place Speaker: Alex Posada, Project Engineer, Campbell Soup 12:00 to 1:00 p.m.

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

Global Manufacturing Innovation From the Merger of Giants Speaker: Diane Wolf, Global Vice President, Safety and Environmental Sustainability, Kraft Foods Integrating Cadbury, one of the world’s biggest confectionery companies, with Kraft Foods, one of the world’s largest food companies, is an immense challenge. This presentation will explain how Kraft Foods is creating a “best of the best” approach by aggregating and implementing best practices from operations in 160 countries to achieve manufacturing excellence around the globe. 1:45 to 2:30 p.m

Developing a Food Quality Protocol

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

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

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

Building and Maintaining Success in Energy Conservation Speaker: Daniel Fonner, Senior Manager, Global Utilities, Heinz North America The enthusiasm for sustainable manufacturing practices can sometimes be squashed by energy initiatives with high up-front costs. This speaker will focus on overlooked opportunities with solid paybacks. 9:00 – 9:45 a.m.

Maximizing Your Corporate Social Responsibility Plan Speakers: Ed Delate, Vice President Global Engineering and Corporate Social Responsibility, Keystone Foods and Dennis Treacy, Senior Vice President of Corporate Affairs and Chief Sustainability Officer, Smithfield Foods Worker involvement and buy-in are critical for an effective corporate sustainability program. These speakers will discuss how educating both employees and suppliers, and encouraging changes in their behavior, can result in tremendous potential for reducing resource consumption. 10:15 – 11:00 a.m.

Quantifying Your Energy Inputs Speaker: Peter Truitt, President, Truitt Brothers This session will help participants understand how much energy is used to make products at any given time and more importantly, the cost of those energy inputs for a finite period. Learn how to effectively manage your energy usage and costs as well as your greenhouse gas emissions. 11:00 – 11:45 a.m.

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

Conference Adjourns

QUESTIONS? Contact Marge Whalen, Senior Event Manager at 630-694-4347 or [email protected]

Driving new ideas at Ruiz Foods are (L-R) Bryce Ruiz, president & CEO; Fred Ruiz, co-founder and chairman emeritus; and Kim Ruiz Beck, chairman.

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www.RFFmag.com

ON THE FAST TRACK BY BOB GARRISON veryone needs a road trip from time to time. And it doesn’t matter whether you’re talking about two people, three, four … or even hundreds. When NASCAR’s Nationwide and Sprint Cup series came to Los Angeles last October, officials at Ruiz Foods, Dinuba, Calif., put the word out. They invited all executives and employees for a road trip to see the events – and ended up taking a busload of nearly 350. Why drive for hours … just to see more people driving for hours? It turns out Ruiz has teamed with Stewart-Haas Racing (SHR) to sponsor SHR driver Ryan Newman. The 33-year-old Indiana native represents Ruiz Foods’ new retail snack brand, Tornados, in Sprint Cup competition. And for that one weekend at Fontana’s Auto Club Speedway, Ruiz also sponsored Newman in a Nationwide series car featuring the company’s El Monterey brand. In addition to the races, NASCAR treated Ruiz team members to hospitality events, garage tours and pace car lap activities. (A month later, approximately 250 team members at Ruiz Foods’ Denison, Texas, plant enjoyed the same NASCAR treatment in Dallas.) Refrigerated & Frozen Foods visited Ruiz just a week after the California races. Back in Dinuba, family members said the event was well worth a five-hour, 250-mile drive south to Fontana from Dinuba (near Fresno).

Photos courtesy Ruiz Foods

E

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New packaging, product positioning and brand promotion drive Ruiz Foods’ growth. “People struggle to understand the secret of our success and they ask me about it all the time,” says a smiling Fred Ruiz, co-founder and chairman emeritus. “We’re something of an anomaly as a family business. There’s just a chemistry involving the family, our executive team and our team members. We share information and do everything together. “Just think. More than 300 team members got on a bus at 2 in the morning to do this [NASCAR trip.] For many, this was their first exposure to the NASCAR and after visiting the hospitality tent, touring the track and more, they had a great time and the full experience. It really created a teambuilding atmosphere.” Fred’s father was company co-founder Louis Ruiz. Asked how Louis may have responded to such an event, Fred replies, “Ruiz Foods grew to surpass anything my dad ever thought it would be. The most important thing he talked about was that we build a brand. He also talked about investing in your business, automating and becoming a lowcost manufacturer. . . If we could build a brand and do that, we could compete against anybody.” NASCAR still was a young and relatively unknown sport in early 1960s when Louis and Fred decided to start producing and selling frozen Mexican foods to mom-and-pop grocery stores in the San Joaquin Valley. Just as NASCAR has grown since then (now sanctioning more than 1,500 races at more than

Refrigerated & Frozen Foods JANUARY 2011 33

100 tracks in 39 states and Canada), so too has Ruiz. From its first days of producing bean and cheese enchiladas and chili rellenos, 46-year-old Ruiz Foods now employs approximately 2,500 people who process more than 200 retail and foodservice items at three facilities in Dinuba and Tulare, Calif., and Denison (see “Inside the plant” feature, p. 40). Refrigerated & Frozen Foods estimates that this third-generation company now boasts annual sales of as much as $450 million. Hispanic Business magazine ranked Ruiz as the sixth largest Hispanic-owned company in the United States and the largest in California. A 2006 inductee into the industry’s “Frozen Food Hall of Fame,” Fred Ruiz since has handed the responsibilities of president and chief executive officer to his elder son, Bryce. His elder daughter, Kim Ruiz Beck, is chairman. “My dad always said, ‘If you’re not growing, you’re dying,’” says Fred. “As a result, we were very opportunistic and growth oriented. Today, Bryce and Kim have embraced the Ruiz family legacy and are as driven as my dad and I ever were. “I don’t exactly know when we became a national company but there is a different dimension now,” he adds. “Bryce is not limited by the past and I think that it’s an advantage.

AT A GLANCE: RUIZ FOODS OFFICES: Dinuba, Calif. TOP EXECS: Fred Ruiz, co-founder, chairman emeritus; Kim Ruiz Beck, chairman; Bryce Ruiz, president, chief executive officer ANNUAL SALES: $450 million* PRODUCTS: Approximately 200 frozen entrée, snack SKUs DISTRIBUTION CHANNELS: U.S. retail, convenience store and other foodservice markets. BRANDS: El Monterey, Tornados WEB SITES: www.elmonterey.com and www.mytornados.com FYI: Hispanic Business magazine ranks Ruiz as the sixth largest Hispanic-owned company in the United States and the largest in California. *Refrigerated & Frozen Foods estimate

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Sometimes the past can be a burden and be limiting in terms of your outlook.” “I’ve inherited a sustainable business,” notes Bryce. “I don’t have the burden of asking whether we can simply make payroll and pay the light bill . . . Yet we’re working just as hard and with a sense of urgency. It’s just that we’re taking our time to be more selective and strategic about where and how we push the business.” Ruiz Foods’ outlook is certainly bright entering calendar 2011. Officials cite Information Resources data to note that Ruiz leads the frozen Mexican foods category with the largest dollar growth of any of the top 10 brands during a 52-week tracking period ended Nov. 28, 2010. Moreover, officials say El Monterey is the dominant brand within the frozen Mexican category -- leading all burrito brands with a 10.5 percent dollar sales increase during the same 52-week period. Last but not least, Ruiz officials say Tornados snack sales have doubled since the product debut in 2005. Still more facts and figures have Bryce Ruiz talking. “We know that our [El Monterey brand’s] awareness is low – relative to other frozen food brands,” he says. “Yet we wanted to look at it in the context of all frozen prepared foods – taking away dairy, fruit and vegetables, etc. – to see how relevant we are. “We have Information Resources consumer research that shows El Monterey is No. 11 among the top prepared food brands,” he says. “Moreover, of the top 20 frozen prepared foods brands, El Monterey is growing by 5.3 percent, which at the second fastest rate. That tells us there’s still a lot of opportunity and that El Monterey is still a new idea in most households. We’ve been at this for so many years and just didn’t realize that our brand means as much as it does.” Behind the scenes, Bryce admits that he has learned so much more. A key moment? When corporate sales asked for advanced sales planning schedules (more than a year out), it resonated and prompted Ruiz Foods’ new leader to shift his mindset. “Today, we’re looking out further,” says Bryce. “When you think more strategically, you can better utilize your funds. Although marketing and sales teams have not grown, we’re doing more and becoming more focused on our core. Our theme is, ‘Fewer. Bigger. Better.’ Let’s do fewer things, think bigger and then execute to a T.” Recognizing that its retail and foodservice brands simply need a greater presence with customers – and more trial and exposure with consumers – Ruiz Foods channeled most of its 2010 spending to new packaging as well as brand advertising, promotion and social media activities. Even Ruiz Foods’ biggest new product splash, the retail launch of Tornados snacks, did not involve much product development. The three-ounce, hand-held snack already has been a hit for six years at convenience stores, stadiums and other nontraditional foodservice venues (see “Less is more,” p. 36). For the record, Ruiz launched a six-item retail Tornados line in

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It’s a changing, fast-paced market, a market where your information needs are just as critical as inventory moves. That’s why United States Cold Storage has revolutionized its eUSCOLD Online Services. In fact, some of the nation’s leading food processors helped us develop this interactive new web site that offers users more than 30 Key Performance Indicators (KPI’s) along with dashboard alerts, metrics, charts and enhanced search and selection features. Whether you need information to prepare a report – or you simply want to see how we’re doing – the data you need will be right at your fingertips. We are The Logistics Network that Works for You.

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January 2010. A new 8.4-ounce retail box contains three servings and carries a suggested retail price of just $2.79. Tornados give Ruiz more elbow room to branch out from Hispanic flavor combinations and into broader varieties. Retail Tornados flavors include Ranchero Beef & Cheese, Grilled Chicken & Cheese, Chicken Club, Southwest Chicken, Cheesy Pepper Jack and Cheesy Pepperoni. And that was just the beginning. Ruiz came back in May with an even larger main line packaging shift that emphasizes multi-serve, snacking occasions. “When we developed new packaging for El Monterey Flour and White Corn Taquitos, we switched from a box to a stand-up, re-sealable bag – and consumers went crazy for it,” says Mark Hannay, senior vice president of retail sales. “One after another, each focus group asked, ‘Why didn’t you do this earlier? Your products are extremely easy and convenient to heat and eat and, now your packaging is just as easy.’” Those insights led Ruiz to repackage 12 different El Monterey retail products – everything from six-count tamales and quesadillas to 14- and 16-count taquitos and mini chimichangas. Ruiz also took the opportunity to upgrade all packaging graphics and photography for the first time. “This takes all the complexity out for retailers,” says Hannay. “No longer will we have one-off items, such as tama-

les, in meat-style trays. Now we can bundle all of our El Monterey brand equity with a common look and common price points. This will give us greater presence across a full door, while it makes it easier for retailers to feature and display our products.”

Media maneuvers Whereas Ruiz identifies NASCAR dads as its core c-store shopper, officials know they need to tell moms and kids about the new Tornados retail line. That led officials to develop the company’s first the multi-media promotional campaign – complete with in-store merchandising materials, social and digital media and 30-second TV ads (themed “Full Force Flavor. Full Force Fun.”) in spot metro markets. “This was a case where – because you have family working this business – we allocated the extra funds,” says Bryce. “Although a national ad campaign was not in the plan, it reflects the family’s commitment to our brands.” A young dad himself, Bryce, 35, actually led Ruiz Foods into social media – first creating a Facebook page for Tornados fans, and then a second page just for El Monterey. “I quickly understood the potential of social media for our brands,” he says. “And looking back, I believe I was right. In 2010, our two brands received more than 2 billion impres-

sponsorship with Stewart-Haas Racing (SHR) in late 2009. Today, SHR driver Ryan Newman drives a Tornados car in More sales. More products. More SKUs. More promotions. NASCAR’s popular Sprint Cup series. Talk to any salesperson and you’d expect to hear that bigger is “We needed a big idea. We needed to own the roller grill always better . . . right? with more than new flavors,” admits Bryce Ruiz, president Not necessarily. Just ask Kimberli Carroll, Ruiz Foods’ vice and CEO. “NASCAR just fits. It was the president of foodservice sales and marketing. right time to get into the sport and we did “Although Ruiz has developed some it with the right team. It allows us to betnew items … we’re focusing on our estabBite Into ter talk to that c-store dad who’s a lished Tornados line (a snack developed in AVOceR FLCh BIG an ur Yo d an NASCAR fan.” 2005 especially for c-store roller grills),” Win a to To effectively “activate” the promoshe says. “We believe there are more tion, Ruiz last year tied its NASCAR growth opportunities – for us and for our sponsorship to a convenience store-level customers – by providing the right prodom mytornados.c “Ride of a Lifetime” sweepstakes, uct programs and merchandising tools to GRAND PRIZE IN INCLUDES: NCLU accompanied by in-store merchandising help customers sell more. We think that programs. Carroll says store operators less is more. welcomed the program, which promises “Our customers don’t need more comto be even bigger this year. plexity,” she continues. “Our biggest chalMeanwhile, Ruiz continues to look lenge simply involves executing to help cusPromotion drives c-store sales, ahead. Every year, for example, it hosts a tomers create awareness and manage shrink. Tornados brand message. retailer roundtable during the National We’re also offering resources, such as planoAssociation of Convenience Stores’ annual convention. grams, to help them plan store merchandising and understand “Our customers are always looking for something new consumer traffic.” and we’re always listening to learn more about where they’re Ruiz also supports customers by promoting Tornados. For going and how we can provide the right tools and products,” starters, Ruiz offers as many as 16 flavor varieties to appeal to says Carroll. “Even so, we always want to help them stabilize consumer tastes across all dayparts (including breakfast). Then the grill area, which has built the business.” Ruiz truly put the pedal to the metal when it inked a NASCAR

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NO PURCHASE NECESSARY. Void where prohibited and in Puerto Rico. For full Official Rules, by whic which cch this sweepstakes swee is governed, go to: www.mytornados.com/Ride. Must be 18 or older and a legal resident of the U.S. Promotion Promotio on en nds 8/12/2011 n 8/12/20 @11:59:59 p.m. ET. ends

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S U C C E S S

S T O R I E S

HOW A VEMAG DEPOSITOR

helped produce a H I G H E R Q U A L I T Y,

E X A C T- W E I G H T FILLED PRODUCT A TRUE STORY: A producer of premium Mexican foods had problems depositing fillings onto tortillas. Their piston depositor only worked if the fillings were soupy and flowed easily. However, they wanted to use thick, cold, chunky fillings to produce a more natural looking product. They also desired precisely portioned fillings with an exact weight and shape so that they could produce a consistent product. At this point, they turned to Reiser. The solution was our Vemag Depositor with a high-speed cutoff device and a sensor to automatically detect the tortilla as it was conveyed. The Vemag was able to transport the thick filling extremely gently while delivering exact-weight portions. As our customer grew and increased production, they looked at automated tortilla rolling and folding options. When they found their solution, Reiser engineers developed a high-speed depositing system to take full advantage of the increased capacity – without sacrificing quality or weight control.

T H E V E M AG WA S CHO S E N I N P L AC E O F T H E P I S T ON F I L L E R Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

Leading the food industry in processing and packaging solutions.

PARTY WITH A PURPOSE Talk to Ruiz Foods officials and you learn the company’s definition of “family” extends well beyond its corporate walls and into its team members’ communities. That led Ruiz to create an entirely different non-profit organization, Ruiz 4 Kids (R4K), two decades ago. And since 1990, R4K has raised more than $2 million to fund San Joaquin Valley area children’s programs. “We are proud to support area non-profit organizations,” says Ruiz Chairman, Kim Ruiz Beck. “They work hard to serve the needs of area children and youth.” Most recently, R4K raised $197,000 in a single event last November. A dinner, silent auction and dance – one of two annual fundraising efforts – drew more than 600 people to the Visalia (Calif.) Convention Center. When it was over, Ruiz 4 Kids portioned out all proceeds to the Boys and Girls Club of the Sequoias, CASA of Tulare County (Calif.), Family Services of Tulare County and the Visalia Police Activities League. “We couldn’t be more pleased with the results of our 2010 fall fundraiser when we recognize the funding cutbacks affecting organizations serving children,” says Ruiz Beck. “Although we see some ease in the economic crisis, it will take longer for non-profit organizations – particularly those depending on donors and grants – to recover.”

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Snack attack. Proven snack a platform for Ruiz to try new flavor profiles.

sions and drove more than 3.5 million brand engagements on Facebook. “I love this medium,” he continues. “It gives us a way to ‘activate’ our brands and engage our consumers. It gives us a platform where we can solicit flavor ideas, recipes and even have some fun with our fans. We also found that the average fan spends five to seven minutes interacting with the medium.” Ruiz used Facebook to launch as many as seven Tornados promotions last year. Although all the Facebook efforts gen-

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Stand up and be counted. New resealable bags add snacking appeal, full-line presence.

erated gains in the fan base, most were designed to spur “active engagements,” officials say. Ruiz notes that its most recent promotion was the first to run in tandem with TV and digital banner ads for “Full Force Flavor. Full Force Fun.” Running from September through November, 2010, the Facebook promotion increased fan base by nearly 100,000 with active engagements of approximately 900,000, officials say. Ruiz encouraged fans to enter and/or vote on “full forced” faces to win prizes from a prize vault.

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Ruiz also was used Facebook to promote El Monterey. The company’s ongoing “uWin Instant Win Game” has both retail and Facebook components. The retail, store-level program features specially marked El Monterey products, which offer consumers the opportunity to win one of more than 10,000 prizes. Consumers also can complete an entry form on the brand’s Web site. This promotion runs through March 31, 2011. Officials say the El Monterey “uWin Challenge” at Facebook ended Nov. 23, 2010, and generated more than 3 million impressions and more than 300,000 active engagements. It garnered nearly 28,000 new fans in just over 30 days. Asked about her brother, Kim Ruiz Beck, smiles, “He’s more aggressive than me. Particularly when it’s come to marketing initiatives. These are thing we only dreamed about. Now, Bryce is finding ways to make them happen.” Bryce, himself, puts it differently. “We’re not doing anything different from 10 years ago. There may be different [communication] media and different business cycles but the rest is the same. My last name is on the building – just like it is for dad, Kim and our other family members. We believe in this business. Today, it’s just a matter of how we’re going to go about growing it. And then, let’s go!”

Refrigerated & Frozen Foods JANUARY 2011 39

Plant photos courtesy of Ruiz Foods

Quick-change artists BY BOB GARRISON

Ruiz team members hand roll freshly baked tortillas filled with chicken, cheese and Mexican spices for El Monterey Chicken and Cheese Taquitos.

Quick changeovers, new packaging lines help Ruiz Foods’ Dinuba, Calif., plant meet growth demands t’s 202 miles from Beverly Hills’ Rodeo Drive to Ruiz Foods, north over the foothills in California’s San Joaquin Valley. Likewise, Los Angeles and Dinuba are worlds apart in other ways. What the entertainment industry is to Los Angeles, the agriculture industry is to Ruiz Foods, which makes its home in Dinuba. Even so, Brian Miller says there’s not much difference between trendy fashion and frozen foods. “Every day, the complexity increases in our business. You can’t just sell the same box of macaroni and cheese,” says Miller, a 30-year food industry veteran and Ruiz Foods’ senior vice president of supply chain. “Consumers are quite different today and it’s almost as though we’ve become a restaurant. We’re developing new products all the time. Whether it’s out of boredom or something else, consumers demand more flavor and flair.” Of course, new products are literally a big deal for Ruiz Foods. The company’s Dinuba plant spans 260,000 square feet, employs as many as 1,650 team members and processes as many as 200 distinct SKUs for retail, foodservice and club store channels.

I

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Although this 20-year-old plant didn’t take on many new products last year, it dramatically retooled and reconfigured several packaging lines. That’s because Ruiz discontinued several bag-in-box packages and other formats while it converted as many as 12 different foods – everything from tamales to mini chimichangas and taquitos – to stand-up recloseable, zippered pouches. “Many companies would have needed six to eight months to change production and packaging – yet we did it within 90 days,” notes Miller. “We’re definitely a ‘brand-driven’ facility with the same type of mindset and environment as a co-packer. We have to be flexible and oriented toward customer service. We’re going to deliver to our sales and marketing plans – no matter what.” It helps to have a veteran workforce where 511 employees joined the company 10 years ago and another 144 have 20 years of tenure. Since it opened in Dinuba in 1990, (population 20,000), Ruiz has attracted hundreds of people within a 40-mile radius and often employed two generations in many team members’ families. Miller says that kind of ongoing relationship has led to several noteworthy achievements in …

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Freshly made tortillas from the Ruiz bakery travel on cooling racks before being transported to the taquito line.

… employee safety. “Eight or nine years ago, repetitive motion activities put us in a high risk category for workers compensation,” notes Miller. “Then we developed a program involving job rotations, job qualification standards, preventative injury exercises and other disciplines so team members are doing various things throughout the week. Years ago, our injury index was 7 or 8 (injuries per man hour), which was comparable to the industry standard for a company our size. Today, we’re at an index rate of 1.5 and in our shipping area alone, we’ve accumulated more than 3,439 days with no losttime accidents.” … food safety. “We handle allergens and high-risk ingredients such as chicken, beef, pork, cheese, eggs and other items,” notes Miller. “Because of the high risks associated with adulteration or bacteria, we inspect at least 98 percent of all raw materials entering the plant. In 2010, we even exceeded that standard – even though we handle as many as 200 different product SKUs. … first-time quality. “We have a quarterly bonus program with three parameters,” says Miller. “Our goals are 98 percent first-time quality, schedule attainment of 95 percent or better and no equipment damage inflicted by team members. We’re giving more [equipment upkeep] ownership to team members and believe in a system where 1,600 peers help each other achieve success. “Last year, our factory’s average hit 99.5 percent for product ‘right first time.’ We also review first-time quality against a consumer complaints measure. For a factory our size – per millions of items produced – the industry average is five or six pieces per million (drawing complaints). Our goal was 1.3 eaches per million and we achieved just one per million.”

“Fresh-frozen” process To visit Ruiz Foods’ Dinuba plant is to see the operation treat taquitos the same way a frozen vegetable plant handles beans. “We are 100-percent self sufficient,” Miller notes. “This includes our own flour delivery system and a complete fresh tortilla bakery to how we blend our own spices and prepare

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AT A GLANCE: Ruiz Foods ADDRESS: 501 S. Alta Ave.,

Dinuba, Calif.

93618 TOP OPERATIONS EXEC: Brian Miller, senior vice president of supply chain PRODUCTS: Approximately 200 SKUs of frozen entrees, hand-held entrees and snacks for all distribution channels. TEAM MEMBERS: 1,650 FACILITY ACRES: 42 acres (includes corporate offices) SIZE: 260,000 square feet (from raw materials

warehousing, tortilla bakery, production and finished goods storage) PRODUCTION LINES: 6 PACKAGING LINES: 10 SCHEDULE: 24-hours, six days a week with 14.5 hours to 16.5 hours of production alternating with sanitation, preventive maintenance and food safety activities FYI: Ruiz has additional facilities in Tulare, Calif., and Denison, Texas all on the floor within hours ll off our ffillings ll h ffactory fl h just a ffew h of freezing. Even though our products are frozen, we ensure that each is ‘fresh-frozen’ so when a consumer prepares it, it tastes as though it’s been cooked for the first time.” Here’s a look at how Ruiz prepares chicken and cheese taquitos. Ingredient preparation: In the case of first-shift production, pre-batch kitchen team members arrive at midnight to remove cheese and chicken form shipping boxes. Used with four days, these ingredients arrive at the cold mix room and are held at 40ºF to ensure food safety and proper mixing consistency. Following computerized formula print-outs, workers

Refrigerated & Frozen Foods JANUARY 2011 41

RUIZ CELEBRATES FIVE YEARS IN DENISON Some birthday parties include a trip to the local go-cart track. Then, again, they do everything bigger in Texas. So how about a birthday celebration including a VIP pass to a national NASCAR event? Ruiz Foods celebrated its fifth year in Denison, Texas, (north of Dallas) last October with quite a birthday bash. It featured an in-plant luncheon, speeches and a VIP trip for all interested employees to NASCAR’s Texas Motor Speedway. There, Ruiz Denison’s 100 employees could cheer on the company’s own Tornados Sprint Cup car, driven by Stewart-Haas Racing’s Ryan Newman. Having led the Denison start-up for Ruiz Foods, Brian Miller is then add water, spices, green chilies and other vegetables. Once the mixture reaches proper consistency, it’s dumped into a mobile stainless steel tote. Totes are staged in a chilled holding area (and sampled by QA technicians) before use on the production room floor. Tortilla baking: Two outside flour silos feed flour (using an air conveyance system) into Ruiz Foods’ plant on a

El Monterey Chicken and Cheese Taquito recloseable bags are sealed during the packaging process.

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proud of the operation’s achievements. “This area has seen many large processors come and go and when we first arrived, most employees viewed us as just another big conglomerate,” he says. “Even so, we tried to explain that Ruiz is a strong, growing family company, one where they officials still try to call each team member by name. “It was a tough first year and people even reacted with disbelief when we tried to put in our first performance raise,” he adds. “We’ve since had pay increases during each of the last three years and those [announcements] are met with applause and appreciation. And what used to be a tough working environment has completely changed. In fact, we are proud to say we have 62 team members who have been with us all five years.”

batch-volume basis. Pre-set amounts of flour and metered water are released into one of four large, upright mixers. After it’s created, Ruiz transfers the dough to proprietary tortilla equipment. Once formed and cut, tortillas travel onward through a continuous oven, which bakes them in just seconds before they exit at the other end. Wire conveyors then allow the tortillas to cool slightly before employees remove, stack and stage them for subsequent use on the line. Process filling: Team members transfer filling mixtures into filling machines positioned beside each filling line. Once tortillas are placed on the production belt conveyor, they receive filling, are quickly folded and rolled (this process is proprietary). Process frying & freezing: Rolled, filled tortillas pass into a continuous fryer, which cooks them for approximately 30 seconds. Although it’s only a matter of a few feet, workers check the newly created (now golden brown) before they travel into a spiral freezer. Packaging & palletizing: Taquitos travel upward and exit the freezer at Dinuba’s second-story packaging room. Here, Ruiz packs them in new stand-up, recloseable pouches; applies code date registration and feeds them to automated casepacking lines. Ruiz also adds its own outer case labels to

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track product in the plant’s adjacent storage freezer. Even as pallet loads ship out to Ruiz Foods’ third-party distribution network, Miller says he and Dinuba team members remain focused on the next load to come.

DINUBA’S 2011 “TO-DO” LIST - Streamline product handling / movement: “Our products require lots of material handling because we don’t believe in “pump-in-place” fillings,” says Miller. “We emphasize [ingredient] piece integrity, which is one way we differentiate ourselves with high quality. Still, we need to find ways to streamline product movement with less handling.”

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

The small footprint aids installation in areas with limited space Double sided viewing allows an even detection of subtle defects from two sides

- Changeovers: Miller says each Ruiz production line is flexible enough to process as many as six to eight different items. Even so, one goal is make changeovers even faster, simpler and “more effective” – with less waste and higher productivity.

Advanced PROfile technology enables removal of defective material by viewing the product using shape characteristics Stainless steel open construction design ensures high hygiene standards and easy cleaning

- Continuous improvement: Crossfunctional employee teams will review Dinuba operations for process improvements. Miller says the goal is to identify more proactive cases where Ruiz can prevent a potential problem – instead of later reacting to that issue. - Plan for more new product, packaging lines: Miller says Ruiz Foods’ successful transition to stand-up pouch has officials considering even more new product and package applications – without expanding Dinuba’s existing factory footprint.

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“We always challenge ourselves to come up with new ideas,” he says. “Our supply chain goal is to be the industry’s leader and ensure the best experience for any consumer buying frozen Mexican foods and flavorful frozen snacks.”

The UHMW PE chute feed system delivers frozen product to the optical vision system efficiently Consistent performance without daily calibration ensures a low maintenance requirement High quality color sorting permits both gross and subtle color blemishes to be removed

Safe Food. Clean Food.

Refrigerated & Frozen Foods JANUARY 2011 43

BY KERI SAPP

Cold Energy Management

Photo courtesy: Digital Lumens Inc.

See the light New cold lighting technologies offer greater energy efficiency, control.

LED lighting handles cold temperature environments, saves energy.

ardon the play on words but it’s time to shed some light on an important topic. Because lighting accounts for 30 percent or more of a building owner’s energy costs, it’s important to keep up with new industrial lighting advances. Some of the industry’s most interesting developments involve greater efficiencies, controls and new technologies. There is no “one-size-fits-all” lighting approach, so each owner must review options and choose the best solution for their individual operation.

P

Lighting landscape Cold food processing plant operators traditionally have used high energy, 400watt metal halide systems 24 hours a day, seven days a week. Thankfully, there are multiple options to reduce that energy use. Dimmable high intensity discharge (HID) retrofits might be a good choice for existing facilities if fixture configurations cannot be changed. Lightemitting diode (LED) lighting also is an excellent choice for cold applications, because we’ve found that this type of lighting operates more efficiently and lasts longer in cold temperatures. Although the initial purchase cost of LED fixtures is still relatively high, those prices are coming down as more commercial sectors utilize the technology. www.RFFmag.com

Cold storage warehouses typically control their lighting with a significant amount of “off” time. T5HO fluorescent lamps and fixtures – with integral occupancy sensors – are the standard choice to provide maximum “off” time using fluorescent technology. Facility owners with these lights need to ensure that fluorescent ballast and lamp combinations are rated for the lowest temperature of the space to be illuminated. Once again, LED’s may be an excellent option for this application because LED lamp life is not shortened by each “on-off” cycle. Facility operators most often overlook issues of lighting control and maintenance. Lights are the most energy-efficient when they are turned off, so the selection of the fixture is only part of the lighting solution. Newer electronic HID luminaries offer dimming capabilities, reducing energy used by HID lighting by as much as 40 percent. Fluorescent fixtures can be effectively step-dimmed or switched on and off via occupancy sensors. Many LED fixtures include occupancy sensors and/or networkable dimming drivers to provide multiple control options. One other important new development involves lighting controllers and building automation systems. These

systems can intelligently switch or dim entire lighting circuits through contactor panels or addressable circuit breakers in lighting panelboards. The technology may be based on time schedules, occupancy sensors or daylight sensors.

Retrofit savings options Facility owners and operators frequently want to know what type of savings they can generate with a lighting retrofit project. In this instance, we can best describe potential savings as we compare one lighting type to another. For example, T5HO fluorescents can offer as much as a 50-percent energy savings over 400-watt metal halide systems. LED’s can offer 60-percent energy savings over the typical 54-watt T5HO fluorescent systems. One cold storage operator’s retrofit program yielded a 95-percent reduction in total lighting energy costs. In this instance, we suspect they had older 400-watt metal halides and switched completely to LED’s. Operators can realize additional savings with dimming and occupancy controls. Likewise, it’s important to talk to your electric utility about programs and rebates linked to energy efficiency initiatives. Utilities are offering rebates to  commercial enterprises in some locations.

Refrigerated & Frozen Foods JANUARY 2011 45

Cold Energy Management

Thinking LED? Consider this. - Supplier longevity. A manufacturer’s industry longevity speaks to their ability to offer and support robust warranties. Suppliers typically offer warranties of between five and 10 years on the LED’s themselves. - Heat sink technology. What heat sink is involved? LED junction temperatures need to be kept as low as possible for extended performance. A heat sink that provides the maximum heat-conduction surface area will provide the best LED cooling. - Fixtures. Select fixtures that are U.L. or E.T.L. listed for compliance as an electrical assembly. - Testing. Choose LED’s tested to IESNA LM-79 and LM-80 standards. This ensures that performance data provided for the fixture was derived through industry accepted standardized testing. - Quality ratings. Investigate your potential suppliers. With so many new companies entering the market, choose fixtures assembled with LED’s produced by manufacturers with excellent quality ratings. Source: K. Sapp, Jacobs Engineering

labor, material, disposal fees and system downtime. Owners also need to consider potential injuries associated with overhead work as well as possible product contamination related to light maintenance and/or installation.

Technology options Looking forward, we expect some of the industry’s biggest improvements will come in LED technologies. We project that fixture costs, features,

Photo courtesy: Rig-A-Lite Industrial Lighting

Do not forget about exterior site lighting. LED’s are an excellent choice for outdoor use because they emit no infrared or ultraviolet radiation (UV light attracts insects). In this instance, we have seen operators generate significant savings by using exterior lighting designed with LED fixtures. When considering a lighting retrofit or new installation, don’t overlook long-term maintenance expenses. Every lighting system installation involves

Consider sanitation, food safety related to light maintenance, replacement. 46

Refrigerated & Frozen Foods JANUARY 2011

styles, applicability, and light output all continue to improve. Of course, LED lighting is the most recent industry innovation and continues to see output improvements. There are commercially available outputs as high as 130 lumens/watt while outputs as high as 250 lumens/watt are in test phase. There are LED fixtures rated for use in a broader range of areas including 1200 psi washdown rated, wet location rated, food processing application, and highand low-bay use. Elsewhere, we see electronic HID – such as metal halide luminaries – now available with improved controllability and energy efficiency features. Wireless lighting control can now be applied in some specific applications. Looking ahead, market researchers project that the global LED lighting market will become a $14 billion industry by 2013. The U.S. market currently accounts for $1 billion of that market, with projected growth to $3 billion by 2013. LED’s are here to stay; but what are the basics? LED’s are a natural fit for cold facility applications. They perform longer and more efficiently at cold temperatures because their light output is based on solid-state technology rather than by gas excitation. Fluorescent and HID lamp life is shortened with every on/off switching cycle – while LED’s are rated for 50,000 to 100,000 hours of operation, regardless of switching cycles. Fluorescent and HID lighting are more mature technologies, so there are smaller improvements in these areas. In contrast, LED technology is growing rapidly, which suggests that costs will decrease while innovations continue at an accelerated pace. Keri Sapp, P.E., LEED AP, is a senior electrical engineer with Jacobs Engineering’s Food and Beverage Process Group, Fort Worth, Texas. Sapp has 20 years of industrial processing and facility design experience, including refrigerated food plants and distribution projects. Readers may call (800) 570-1985 or visit www.jacobs.com for more information. www.RFFmag.com

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

Cablevey Conveyors

EVAPCO Inc.

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

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

Since its founding in 1976, EVAPCO, Inc. has become an industry leader in the engineering and manufacturing of quality heat transfer products around the world. EVAPCO’s mission is to provide first class service and quality products for the following markets: • Industrial Refrigeration • Commercial HVAC • Industrial Process • Power EVAPCO’s powerful combination of financial strength and technical expertise has established the company as a recognized manufacturer of marketleading products on a worldwide basis. EVAPCO is also recognized for the superior technology of their environmentally friendly product innovations in sound reduction and water management. EVAPCO is an employee owned company with a strong emphasis on research & development and modern manufacturing plants. EVAPCO has earned a reputation for technological innovation and superior product quality by featuring products that are designed to offer these operating advantages: • Higher System Efficiency • Environmentally Friendly • Lower Annual Operating Costs • Reliable, Simple Operation and Maintenance With an ongoing commitment to Research & Development programs, EVAPCO provides the most advanced products in the industry – Technology for the Future, Available Today!

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

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

Contact: EVAPCO, Inc. Ph: 410-756-2600 Fx: 410-756-6450 www.evapco.com

Visit us at IPE Booth # 4343 www.refrigeratedfrozenfood.com | Refrigerated & Frozen Foods | January 2011

47

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

Intralox, L.L.C.

JBT FoodTech

Intralox, L.L.C., is a global manufacturer specializing in conveying technologies that solve conveyance problems, simplify processes, and save money for customers. The combination of our service infrastructure, industry expertise, innovative technology, and performance guarantees allows our customers to achieve extraordinary results. Spiralox® solutions from Intralox are ideal for freezing and cooling applications, offering extended belt and component life, reduced maintenance, improved energy efficiency, and reduced product loss. The new Series 2800 Spiralox GTech is a green spiral belt that is stronger, stiffer, and more energy efficient than any other modular plastic spiral belt. It’s an ideal choice for processors who want the proven benefits of Intralox modular plastic belting, along with the additional benefits of increased beam strength, better airflow, and tighter transfer capability. The Spiralox GTech belt outperforms other belt designs in spiral proofers, freezers, and coolers. Committed to quality and performance-driven results, Intralox offers customers worldwide expertise and world-class service. Spiralox® Optimization Solutions (SOS) helps customers reduce their total cost of ownership and lower their overall risk in large-scale spiral retrofits. Through a stepby-step documented process, Intralox takes 100% ownership of the entire retrofit project and delivers a comprehensive, single-source spiral solution to existing spiral inefficiencies.

JBT FoodTech, a leading supplier of food processing solutions ranging from single machines to integrated processing lines, continues to improve its systems and strengthen its global partnerships to help processors meet their needs for quality, efficiency and yield. Poultry processors can find custom solutions to their specific needs with proven systems like the DSI Consistent Thickness Slicer™, Stein Ultra V™ Breader, Stein 5 Star Home Style™ Breader, Stein TFF THERMoFIN® Fryer, Stein GCO-II GYRoCOMPACT® Oven and Frigoscandia GYRoCOMPACT® M10 Tight Curve Spiral Freezer, among Double D others. Most recently – and Searer/Grill new since the last IPE show – Marker JBT FoodTech is offering the MX-II, a next-generation MicroMAX™ filter and developed a DSI Adaptive 3D Portioning™ System that combines the new DSI Adaptive Slicer™ and DSI Waterjet Portioning System. In addition, JBT FoodTech now offers the Double D Searer/Grill Marker and is the exclusive sales agent in North America for the Odenberg Pallet-Link® chilling and freezing system. The Odenberg Pallet-Link® system allows for variable retention time and buffering for controlled parameter chilling and freezing of multiple products simultaneously.

Odenberg Pallet-Link® System

Contact Intralox Customer Service to learn more about how Intralox can help you solve problems, simplify processes, and save money.

48

Contact: Intralox, L.L.C. 301 Plantation Road Harahan, LA 70123 Phone: (800) 535-8848 Fax: (800) 877-7543 [email protected] www.intralox.com

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

IPE Booth # 5145

IPE Booth #4639

January 2011 | Refrigerated & Frozen Foods | www.refrigeratedfrozenfood.com

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

Nercon

Petro-Canada Lubricants

Nercon specializes in packaging line engineering and design, controls integration and conveyor manufacturing. Having a great depth of experience in frozen food industries, Nercon’s engineers are proficient at designing fully integrated and automated conveyor lines for frozen food packaging and in extreme cold room temperatures. Nercon has been a conveyor and equipment supplier to the top frozen food manufacturers for more than ten years. For more information, visit www.nercon.com, search phrase “frozen food.” Featured here is a sanitary hopper system which was engineered for Bulk frozen ingredients hopper system handling bulk frozen food in a -20 F manufacturing environment. The system provides the manufacturing process of breaking-up clusters of frozen bulk product, then mixing the ingredients to prepare for salable packaging. Quick sanitation and inspection is provided with rolling, pull-out mechanisms to access the cluster buster apparatus and augers, as well as access panels to other Clust buster designed critical production areas. to break-up clusters The stainless steel, of frozen ingredients bead-blasted, tube frame construction provides efficient cleaning processes Reversing auger in pull-out position for between ingredient changes. cleaning

Frozen bulk ingredients are unloaded into dumpers, and are carefully broke up with specially designed cluster-busters. Then the product is metered onto the take away elevators feeding six hoppers. Product is scaled, measured and controlled to provide bulk mixes from single serving size to 2 lb. packages.

Committed to developing world-class compressor fluids for over 20 years. The Food Processing and Cold Warehousing industries present unique challenges for lubricants. Uninterrupted consistent performance is critical to plant reliability and to maintaining product shelf life. With increasing pressure to improve energy efficiency and reduce costs, maintenance managers face even greater lubricant demands. These are just the kinds of challenges that Petro-Canada thrives on. We have been committed to developing innovative solutions through worldclass refrigeration compressor fluids for over 20 years. Our REFLO line of compressor fluids, recognized globally, delivers reliable performance in a name you can trust. For more than 25 years, Petro-Canada Lubricants has researched, developed and produced over 350 products that are marketed to more than 70 countries. With one of the most sophisticated manufacturing facilities of its kind in North America, we have the infrastructure that ensures our customers can count on a nimble, efficient supply source. When it comes to delivering the ultimate in lubrication, Petro-Canada is a global leader.

Frozen bulk ingredients merge system

®

Contact: Nercon Eng. & Mfg., Inc. Oshkosh, WI USA 920-233-3268 www.nercon.com

Contact: Petro-Canada Lubricants 2310 Lakeshore Rd. W. Mississauga, ON L5J 1K2 Phone: 1-866-335-3369 Email: [email protected] Web: www.lubricants.petro-canada.ca

www.refrigeratedfrozenfood.com | Refrigerated & Frozen Foods | January 2011

49

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

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

50

Tippmann Group / Interstate Warehousing Tippmann Group offers more than 50 years of experience in the refrigeration industry, specializing in construction and management of refrigerated / frozen distribution centers. Interstate Warehousing, a Tippmann Group company, owns and operates 8 public refrigerated warehouse facilities, with more than 73,000,000 cubic feet of storage space strategically located throughout the U.S. Tippmann Group’s construction division provides a fast-track design / build option for construction of a new distribution center, or expansions and renovations to existing distribution facilities. Tippmann also developed the QFR Zone™ (Quick Freeze Racking Zone), a more efficient alternative to traditional blast freezing, which can save warehouses up to 50% on their blast freezing related expenses.

QFR Zone™ Highlights • Cut blast freezing related utility costs as much as 50% • Each QFR Zone is designed to your freezing application with the flexibility to freeze virtually any palletized products • Significantly improved airflow • Dramatically lower labor costs • Faster product turns • Easy access to product when freezing is complete • All product on a pallet is frozen at the same speed • Continuous freezing capabilities, no more batch cycles

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

Contact: Steve Tippmann Executive Vice President Tippmann Group / Interstate Warehousing 9009 Coldwater Road Fort Wayne, IN 46825 (260) 490-3000 (260) 490-1362 / fax www.tippmanngroup.com [email protected]

Visit us at IPE booth # 6545

Visit us at IPE booth # 5649

January 2011 | Refrigerated & Frozen Foods | www.refrigeratedfrozenfood.com

Classified Network

248-786-1692 • [email protected] • Suzanne Sarkesian

CO-PACK MANUFACTURING SERVICES

EQUIPMENT FOR SALE

Contact Us for Fast Flexible Production & Culinary Solutions. Large company process. Small company flexibility. We combine the capabilities and capacity of a large company – rigid food safety standards, culinary ideation, trend identification and stringent quality assurance – with the personal responsive and flexible approach of a small company. Manufacturing Capabilities

• Kettle Production Sauces and Soups • Tray Lines • Rheon® Technology

(up to 4 oz. shapes)

• Hand Rolled Line • Breading Line • Enrobing (Bake/Par-Fry) • Proofing/Baking • Multi-Component Fill

Packaging Capabilities

• Drop-In Pouch Enclosure • In-House Pasta Blanching • Fully Integrated In-House Component Processing • Vegetable Blending • RTE • USDA/FDA Certified • HCCAP Program • X-Ray Scanning • Metal Detection

• Aluminum Tray (3 to 10lbs.) • Dual Ovenable/Microwavable Tray (10 to 44 oz.) • Boil-In-Bag • Gusseted Multi-Component Bag/Film • Steamable Bag/Film • Tray In Carton • Eat Out Of The Box • Bulk Pack

Please visit us at www.ardenculinary.com or www.bellisiofoods.com or call 800-368-7337 for more information on production capabilities and culinary services.

WORK POSITIONER

SFWB Proof Template.indd 1

www.RFFmag.com

Refrigerated & Frozen Foods JANUARY 2011 51

Classified Network

Suzanne Sarkesian • [email protected] • 248-786-1692

EQUIPMENT FOR SALE

Terlotherm Scraped Surface Heat Exchanger Typical applications include (EATINGs#OOLING #OOKINGs0ASTEURIZATION

(856) 241-9970 www.terlotherm.com

WANTED TO BUY

52

Refrigerated & Frozen Foods JANUARY 2011

www.RFFmag.com

Classified Network

248-786-1692 • [email protected] • Suzanne Sarkesian

EQUIPMENT FOR SALE

Refrigerated Containers Practical

Now Renting

Inexpensive

Quick

We sell world wide.

Cryo-Jet® Cooling Fan

Privately owned and operated for over 40 years Kelly can handle your freezer / cooler needs. Ground level, dock height, lighting, walk in doors, insulated rollup doors and custom features available.

• Faster cooling of hot food products using ambient air. • Reduces build up of frost/ice in continuous freezers.

20’x8’x8’6" & 40’x8’x8’6" Three Phase 230/460 volts 50-60 HZ Temp range -15F+40F

Used carriers starting at $9500 New BOHN Coolers/Freezers starting at $10,500 Blast Freezers starting at $34,500

Toll Free: 866-713-6307 • FAX:860-668-2871

www.kellyfreezer.com

E-mail: [email protected] www.foodesign.com Phone: 503-685-5030 Fax: 503-685-5034 PO Box 2449 Wilsonville, OR 97070

FOOD PRODUCT DEVELOPMENT

ESCA Enterprises, Inc. Enhancing Food Industry Products and Profitability

Providing Customized Services to the Food Industry Through:

-PRODUCT DEVELOPMENT -PRODUCTION & QA SUPPORT -MARKETING SERVICES Contact Allan Samson, Ph.D. Phone: 610-558-1902 Fax: 610-558-3306 E-mail: [email protected] www.escaenterprises.com

subscribeforfree.com www.RFFmag.com

Refrigerated & Frozen Foods JANUARY 2011 53

ADVERTISING

ADINDEX Advertiser

Ashworth Bros., Inc

Page

E-mail/Website

7

www.ashworth.com

Patrick Young Publisher & District Sales Manager 600 Willowbrook Lane, Suite 610

Buhler Sortex Inc.

43

West Chester, PA 19382

www.buhlergroup.com

[email protected] Tel: 610-436-4220, ext. 8520; Fax: 248-502-2123 Mid-Atlantic Territory: CT, Eastern PA, NJ, NYC

Cablevey Conveyors

24

www.cablevey.com

Demaco

39

www.defranciscimachine.com

and LI, VA, MD, DE, Washington DC

Paul Kelly District Sales Manager 1050 Illinois Rte 83, Suite 200 Bensenville, IL 60106-1048

Evapco Co.

3

www.evapco.com

[email protected] Tel: 630-694-4336; Fax: 248-502-1017 Midwest and Northeast Territory: Northern IL, WI, MN, IA, KS,

The Fricks Company Hinds-Bock Corporation

26, 28

www.thefrickscompany.com

22

www.hinds-bock.com

MO, SD, ND, CO, WY, NE, TX, OK, NM, AR, NH, VT, MA, RI, ME, Saskatchewan

Brian Gronowski District Sales Manager 13973 Meadowlark Ln. Newbury, OH 44065

Intralox

2

www.intralx.com

[email protected] Tel: 440-564-5732; Fax: 248-502-2088 Midwest and Southeast Territory: OH, IN, WV, KY, TN, MI,

JBT FoodTech Nercon Engineering

NY, Western PA, FL, GA, NC, SC, AL, Southern IL, MS, LA,

16-17

www.jbtfoodtech.com

21

webinar.foodengineeringmag.com

Ontario, Quebec

Wayne Wiggins, Jr. District Sales Manager 454 Funston Avenue San Francisco, CA 94118

Petro-Canada Lubricants

10-11 www.lubricants.petro-canada.ca

[email protected] Tel: 415-387-7784; Fax: 415-387-7855 West Coast Territory: AZ, CA, OR, WA, AK, UT, ID, HI,

Raque Food Systems, Inc.

5, 27

British Columbia

www.raque.com

Suzanne Sarkesian

Request Foods

29

Internet and Classified Sales Manager

www.requestfoods.com

[email protected] (248)786-1692

Reiser

19, 37

www.reiser.com READER & MARKETING SERVICES

Tippman Group

13

www.tippmangroup.com

Tygard Machine

23, 38

www.tygardclaw.com

35, Back Cover

www.uscold.com

25

www.ynotfoods.com

United States Cold Storage, Inc. Y Not Foods

LETTERS Bob Garrison Refrigerated & Frozen Foods 155 Pfingsten Road Suite 205 Deerfield, IL 60015 [email protected] BACK ISSUES Hallmark Data [email protected] (847)763-9534 SINGLE COPY SALES Gisele Manelli [email protected] (847)405-4061

REPRINTS Jill Devries [email protected] (248)786-1596 Untitled-1 1

8/27/10 10:23 AM

Refrigerated & Frozen Foods 155 Pfingsten Road, Suite 205 Deerfield, IL 60015 Phone: (847) 405-4000 | Fax: (847) 405-4100

Also publishers of: Food Engineering, Food Master, Food Automation and Manufacturing Conference and Expo and ProcessTechnologyXchange

LIST RENTAL For postal information, contact Rob Liska at 800-223-2194 x726 For email information, contact Shawn Kingston at 800-409-4443 x828

The Logistics Network That Works For You UNITED STATES COLD STORAGE, INC. Services Include: Freezer/Cooler Storage • Blast Freezing • Import/Export Services Documentation & Stamping • U.S. Customs Bonded • Transload Services Rail Services • Order Picking • Freight Consolidation/Distribution National Transportation Services

USCS SOLUTIONS Offering strategic new distribution center locations and greatly expanded national logistics services, USCS is moving efficiently to anticipate and meet the refrigerated supply chain needs of processors, manufacturers and distributors across the country.

· National transportation · Carrier management and compliance · Transportation savings and operational simplification

· Shuttle services · Dedicated transport manufacturer to DC · Equipment and drivers provided and professionally managed

Please contact us for more information:

Keith Mowery, Director Transportation & Logistics [email protected]

Headquarters Tel 856.354.8181

|

Tom Hrivnak Logistics Operations Manager [email protected]

National Sales Tel 510.471.1703

|

www.uscoldstorage.com