Refrigerated & Frozen Foods September 2011

SEPTEMBER 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

FROZEN FOOD

PROCESSOR OF THE YEAR

LOGISTICS RFF’S GREEN AWARDS

ENERGY SAVE WITH CO2 Supplement to Food Engineering a

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Touching Everyday Life

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SEPTEMBER 2011

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11 COLD ENERGY MANAGEMENT Refrigerate and reduce Carbon dioxide refrigeration technology can reduce cost, energy in the right applications.

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17 COLD PACKAGING One-stop shopping, learning Packaging show promises all the latest trends, technologies in one location.

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20 COLD SUPPLY CHAIN & LOGISTICS On the right track Refrigerated & Frozen Foods honors poultry, potato processors for green supply chain achievements.

24 COLD TECHNOLOGY SHOWCASE Highlight on new conveyors and belting, form/ fill/seal packaging equipment for refrigerated and frozen food processing plants.

34 COVER FEATURE

Frozen Food Processor Of The Year

AdvancePierre Foods

Sign of the times Acquisitions, product and process innovation help newly formed AdvancePierre Foods make a name for itself in frozen prepared meats, sandwiches.

42 COLD OPERATIONS Fired up AdvancePierre Foods aims for operational excellence in every growth stage.

46 COLD PARTNERS IN PROGRESS Reduce labor. Save product. An automatic bagger and scale system helps Canada’s Desco accurately package more chicken with less labor.

42 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.

ON THE COVER: AdvancePierre Foods Chief Executive Officer Bill Toler

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 Ann Kalb at [email protected].

4

Refrigerated & Frozen Foods SEPTEMBER 2011

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VOL. 22, NO. 5

It’s what you build

PATRICK YOUNG Publisher

(610) 436-4220, ext. 8520 [email protected]

EDITORIAL BOB GARRISON Editor-In-Chief

or most, it was just another day on the calendar. Yet August 17 was a day to remember at Cincinnati’s AdvancePierre Foods. That Wednesday morning had officials at a public unveiling for a new corporate logo and sign outside APF’s corporate offices. Big deal? Maybe not to you. Yet there’s a fascinating back story here. For starters, had the right team not come to purchase a bankrupt Pierre Foods business in 2008, this proud local employer (more than 60 years old with more than 1,800 employees nationwide and about 800 in Cincinnati) might have closed. Interestingly enough, Pierre’s purchase by Los Angeles investor Oaktree Capital was named “2008 acquisition of the year” by Mergers & Acquisitions magazine. CPG veteran and CEO Bill Toler quickly and skillfully staffed and reorganized Pierre. By 2010, it was well positioned to merge with complementary competitors Advance Food Company and Advance Brands LLC. That move alone created a $1.2 billion frozen prepared proteins and sandwiches business. Still more quick and savvy maneuvers had AdvancePierre ready in June 2011 to acquire retail frozen chicken specialties processor Barber Foods. AdvancePierre now stands as a $1.5 billion business with 4,500 employees at 11 facilities nationwide. That’s why company officials decided August 17 to celebrate the company’s growth and launch APF’s inaugural Volunteer Day event, where employees, families

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and friends at eight facilities donated time to support local non-profit organizations. In addition to the hundreds of hours that AdvancePierre Foods’ employees from Iowa, Maine, North Carolina, Ohio, Oklahoma and South Carolina contributed on Volunteer Day, the company also donated thousands of pounds of AdvancePierre Foods products, including 8,000 pounds of food to feed families and children in Cincinnati. “The Cincinnati community has embraced our company and our employees for more than 60 years, and we remain committed to supporting growth at our headquarters in Cincinnati as well as in communities where our facilities are located across the country,” said Toler. Meanwhile, Refrigerated & Frozen Foods is proud to recognize APF at “2010-2011 Frozen Food Processor of the Year.” As you learn from our coverage starting on page 34, this one-year-old company continues to grow by acquisition and continued investment everywhere you can imagine – from original consumer research, new products and packaging to plant and supply chain improvements and customer support. Personally, I can’t think of a more compelling story line. Moreover, it’s refreshing to see private businesses and families (the Allens, Barbers) find the right partner to keep their businesses and legacy brands moving forward.

Refrigerated & Frozen Foods SEPTEMBER 2011

(574) 935-3724 [email protected]

PRODUCTION SUZANNE FAIRMAN Production Manager

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ADVERTISING PATRICK YOUNG National Sales

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JILL L. DEVRIES Reprints

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Classified Sales

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Carolyn M. Alexander Audience Audit Coordinator LIST RENTAL Kevin Collopy Sr. Account Manager Phone: 845-731-2684 Toll Free: 800-223-2194, ext. 684 Email: [email protected] Michael Costantino Sr. Account Manager Phone: 845-731-2748 Toll Free: 800-223-2194, ext. 748 Email: [email protected] For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail: [email protected] www.rffmag.com

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“The patented tight curve in the GYRoCOMPACT TC Freezer makes high capacity freezing possible in tight spaces.” Who has space for gigantic freezers in plants where there are already equipment traffic jams? Processors need significantly more capacity but in a smaller footprint and that’s where the GYRoCOMPACT M10 TC Freezer comes in. Its 40” belt expands on the outside and collapses on the inside to create a tight radius curve. Add to this an integrated self-stacking belt system creating an enclosed product zone which provides the most efficient and hygienic system on the market today. What’s in it for you? Up to 40% greater capacity in the same footprint, longer run-times, less downtime and turnaround time, increased throughput and more trouble-free production. Call Lee Clarkson to reserve the Tech Center. 419-627-4319

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Cold Energy Management

Photo courtesy of M&M Refrigeration

BY CHUCK TOOGOOD

Third-party energy study documents efficiency of cascade carbon dioxide and ammonia refrigerating system.

Refrigerate and reduce Carbon dioxide refrigeration technology can reduce cost, energy in the right applications. ant to reduce refrigeration system costs and energy at the same time? Cold food plant and warehouse operators should consider cascade carbon dioxide and ammonia (cascade CO2/NH3) refrigerating systems, which are becoming more popular in North America. Is your facility the right candidate for this new type of technology? Before you can answer that question, you have to address a few more. Here’s a starting place: UÊ7…>ÌÊÌi“«iÀ>ÌÕÀiÃÊ`œÊޜÕʘii`ÊÌœÊ “>ˆ˜Ì>ˆ˜¶ UÊ
ÀiÊ̅iÀiÊ«Àœ`ÕVÌÊvÀii∘}ÊÀiµÕˆÀi“i˜Ìö UÊÃʈÌÊVÀˆÌˆV>ÊvœÀÊޜÕÀÊv>VˆˆÌÞÊÌœÊ “>ˆ˜Ì>ˆ˜Ê>ÊÀi`ÕVi`Ê>““œ˜ˆ>ÊÃÞÃÌi“ÊV…>À}i¶ Of course, cost always is an important factor in any project. If your project does not require storage temperatures below 0°F to -4°F (-17.8°C to -20°C) and there is no blast freezing and very little room freezing requirement, the most cost effective and efficient refrigerating option would be a single-stage economized ammonia refrigerating system. However, if your storage tem-

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perature requirements are below -4°F and there is considerable room and or blast freezing requirements, you should carefully consider a cascade CO2/NH3 refrigerating system’s benefits. Depending upon the size of the refrigerated facility, the installed cost of a cascade CO2/NH3 refrigerating system often is less than an equivalent two-stage ammonia system. The primary factors contributing to the lower cost are: smaller low-stage compressors; smaller low-temperature suction piping, valves; liquid separating vessels; less piping and vessel insulation and lower refrigerant (CO2) costs.

Field tests When lower temperatures than mentioned above are required, the operating cost of a cascade CO2/NH3 refrigerating system becomes very attractive. A third-party energy company recently studied results of a cascade CO2/ NH3 system modeled against an equivalent two-stage ammonia system. The project included field installed instrumentation and data tracking equipment to monitor and evaluate the real-time performance of the refrigeration plant. The study included refrigerated storage

spaces and ultra-low temperature blast freezers with ability to operate at temperatures lower than those commonly obtained with conventional ammonia systems. The cascade CO2/NH3 system operates at the following nominal process temperatures (i.e., saturated suction temperatures): -58°F CO2 blast freezing; -20°F CO2 freezer storage; +20°F CO2 coolers and docks; and, +20°F NH3 high stage. The conventional ammonia system was modeled for the following temperatures: -58°F NH3 blast freezing; -20°F NH3 freezer storage; and, +20°F NH3 high stage, coolers and docks. The efficiency of the cascade CO2/ NH3 refrigerating system was measured in kilowatts per ton of refrigeration load (kW/TR). After five months of monitored operation, these were the results of the cascade CO2/NH3 refrigerating system efficiency – compared to the efficiency calculated for the conventional two-stage ammonia system. UÊ/…iÊV>ÃV>`iÊ "2/NH3 combined (-58°F and -20°F suction groups) efficiency shows a 28.7 percent improvement compared to the con- 

Refrigerated & Frozen Foods SEPTEMBER 2011 11

Cold Energy Management

NEW PROJECT PROFILE: ENERGY SAVINGS AT TESTA PRODUCE INC. A broadline distributor of fresh, frozen and canned fruits and vegetables, Testa Produce Inc., is pursuing LEED Platinum certification for its newly constructed 91,300-square-foot distribution center in Chicago. The facility includes separate temperature-controlled refrigeration zones ranging from 0˚F to +60˚F. This includes 7,600 square feet of 0˚F freezer and 24,700 square feet of cooler space. To learn more about the facility’s energy reduction efforts, Refrigerated & Frozen Foods spoke with Michelle VanderDoes, LEED AP O+M, a senior sustainability analyst with Epstein, which served as the architect, civil engineer and LEED project consultant. Q: How does this new facility reduce energy? VanderDoes: Some main energy reduction features involve renewable energy (wind turbine and PV panels), ammonia glycol refrigeration system, efficient lighting, solar tracking and prismatic skylights, occupancy sensors and virtual server technology. Q: How did Testa select those technologies? VanderDoes: Owner Peter Testa was very interested and involved in making these decisions. Many choices were simply based on a favorable return on investment. Others were made as a statement to show Testa’s desire to “set the standard” for produce distribution facilities. Q: What can you tell us about facility controls for ongoing energy management? VanderDoes: Other than the typical controls, which are required for all mechanical systems there are: occupancy sensors, time clocks and daylight sensors. The wind turbine also features meters that monitor and report realtime conditions and the energy production. These data appear on an educational display inside the facility. 12

Refrigerated & Frozen Foods SEPTEMBER 2011

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>““œ˜ˆ>ʈÃÊVœ˜Ì>ˆ˜i`Ê܈̅ˆ˜Ê̅iÊi˜}ˆ˜iÊ Àœœ“Ê>˜`Ê̅iÊVœ˜`i˜ÃiÀʜ˜Ê̅iÊÀœœv]Ê Ì…iÀiʈÃʘœÊVœ˜Ì>“ˆ˜>̈˜}ÊÀivÀˆ}iÀ>˜ÌÊ ˆ˜Ê̅iÊÃ̜À>}iʜÀÊ«ÀœViÃȘ}Ê>Ài>ðÊ/…ˆÃÊ iˆ“ˆ˜>ÌiÃÊ̅iÊÀˆÃŽÊœvÊ`>“>}i`Ê«Àœ`ÕVÌÊ >˜`Ê«œÃÈLiʈ˜ÕÀÞÊ̜Êi“«œÞiiÃʈ˜Ê̅iÊ Õ˜ˆŽiÞÊiÛi˜ÌʜvÊ>ÊÀivÀˆ}iÀ>˜Ìʏi>Ž°Ê >ÃÌÊLÕÌʘœÌʏi>ÃÌ]ʈ̽Ãʈ“«œÀÌ>˜ÌÊÌœÊ Ài“i“LiÀÊ̅>ÌÊ>““œ˜ˆ>Ê>˜`ÊV>ÀLœ˜Ê `ˆœÝˆ`iÊ>ÀiÊLœÌ…ʘ>ÌÕÀ>ÊÀivÀˆ}iÀ>˜ÌÃ°Ê /…iÞÊ`œÊ˜œÌʅ>À“Ê̅iʜ✘iʏ>ÞiÀÊ>˜`Ê `œÊ˜œÌÊVœ˜ÌÀˆLÕÌiÊ̜Ê}œL>ÊÜ>À“ˆ˜}°Ê Chuck Toogood is vice president of business development for M&M Refrigeration, Inc., Federalsburg, Md. Toogood has 45 years experience as vice president of engineering for a national cold storage provider. From 2004 to 2010, he was involved with the design and construction of six cold storage warehouses using cascade CO2/NH3 refrigerating systems.

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Photo courtesy of Packaging Machinery Manufacturers Institute

Cold Packaging Solutions

PACK EXPO Las Vegas will draw an estimated 25,000 visitors including food processors.

One-stop shopping, learning Packaging show promises all the latest trends, technologies in one location. ooking for a great package deal? How about the latest food industry trends and technologies … all packaged up at one time and in one location. That’s the promise of PACK EXPO Las Vegas 2011, September 26-28, at the Las Vegas Convention Center. Organizers expect the event to draw as many as 25,000 industry professionals for three days of industry programs and an exhibition of more than 1,600 exhibitors. Show sponsor, the Packaging Machinery Manufacturers Institute (PMMI), says focus group studies helped it organize the show with a better understanding how consumer and industry trends impact the entire production line. These trends involve food-, employee- and environmentalsafety concerns, sustainability issues and packaging and products considered “unique” by consumers. PMMI says it planned an accompanying three-day conference with more than 45 sessions in related tracks of sustainability, operations, innovation, product safety, best

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practices, workforce development and overall packaging trends. “Consumers demand and reward innovations in products and packages — especially those that deliver convenience, value and safety,” says Charles D. Yuska, PMMI president & CEO. “In September, PACK EXPO Las Vegas 2011 will be home to technologies and concepts from processing and packaging suppliers committed to helping their customers find new ways to address consumer demands and to improve efficiency and productivity — from processing to packaging to warehousing.” Speaking of processing, the September 2011 show marks the debut of processing equipment on the PACK EXPO Las Vegas floor. “Attendees at last year’s PACK EXPO International let us know they were pleased to come to PACK EXPO and find total systems solutions,” says Yuska. “I am certain PACK EXPO Las Vegas attendees will have the same reaction.” Show organizers say they hope 

AT A GLANCE WHAT: PACK EXPO Las Vegas 2011 WHEN: Sept. 26-28 WHERE: Las Vegas Convention Center, Las Vegas, Nev. WHO: PMMI expects 25,000 attendees and 1,600 exhibitors. Visitors include buyers and supplier of packaging and processing equipment, supplies and services for food, beverage, candy and pharmaceutical industries. CONTACT: Visit www.packexpo.com or call (888) 275-7664 (ASK PMMI)

Refrigerated & Frozen Foods SEPTEMBER 2011 17

Cold Packaging Solutions to attract teams of food processing and packaging engineers. The goal is to give engineers complete systems solutions related to efficiency, speed and sustainability. Nestlé Global Technician Procurement Manager Stephane Boubee told PMMI that the expanded show

indeed brings an opportunity to expand his sourcing horizons. “The show allows me to initiate some commercial relationships with suppliers I didn’t know before,” he told PMMI. “PACK EXPO is definitely a ‘must-be-at’ show.” PMMI notes that food industry

Food for thought PACK EXPO Las Vegas educational seminars for food processing, packaging engineers.* MONDAY, SEPT. 26 Theme(s): Sustainability, operations y Innovate for positive results on costs, profits y Develop a sustainable, resusable packaging transport system y Total cost ownership: Brand owner’s keys for managing vendors y Answering packaging line layout questions y Food Safety Modernization Act update & CPG companies’ response y Importance of nondestructive packaging testing y Five faces of innovation: Integrating from concept to consumer y The cost of sustainability y Food safety guidelines: Process validation in low-moisture foods y What’s next in sustainable packaging y Perfect ingredients for packaging innovation y Going green: From “should” to “good”

TUESDAY, SEPT. 27 Theme(s): Workforce development, product safety, sustainability, converting operations y Managing, protecting reusable packaging assets y Packaging HACCP: What to expect from suppliers y Workforce development: Competency models reviewed y Product security in today’s global manufacturing environment y Compensation: Providing value that justifies the money y Sustainability: Gate-to-gate tracking from manufacturing upstream y Blended online, traditional worker training y Understanding third-party auditing certification y Use of UV/EB for food packaging y Find, train, retain the right workers y Food safety & packaging: Hazards, recalls and new strategies y Required packaging GMPs: One voice from CPG companies

WEDNESDAY, SEPT. 28 Theme(s): Trends y Future packaging trends y Mobile moment of truth: Packaging, retail and the engaged consumer y Contract packaging trends *Excludes converting, beverage, drug and medical device sessions

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executives will account for more than 40 percent of all show attendees. Yet regardless of product, PACK EXPO Las Vegas 2011 should deliver solutions from robotics and automation to food safety, filling and palletizing, officials say. The show floor will feature several special areas, including… … Food Safety Summit Resource Center. Organizers say this area will feature industry and subject matter experts who can help processors learn about the latest breakthroughs in food safety and consider innovative ways to implement the Food Safety Modernization Act’s new rules and regulations. … The Processing Zone. Although process equipment will be displayed throughout the show, PMMI says this special pavilion will showcase technologies to enhance food safety, reduce waste, ensure product freshness and improve sustainability. … The Brand Zone. This sold-out area will show food manufacturers the latest container and material innovations related to convenience, portion control, sustainability and more, says PMMI. Exhibits will feature advances in glass, plastic, metal and paperboard as well as decorating and labeling techniques. The Brand Zone also is home to “The Showcase of Packaging Innovations,” sponsored by The Dow Chemical Co.; and a display of “PACK EXPO Selects finalists,” recognizing best-in-class consumer packaging by PACK EXPO Las Vegas exhibitors. “Packaging is critical to brand success,” Yuska concludes. “Attendees will find packaging innovations in The Brand Zone that can sharpen their competitive edge at the point of sale. The full spectrum of packaging and processing equipment and components on site will help brand owners easily find solutions to bring innovative concepts to market quickly and efficiently.” www.RFFmag.com

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

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

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Photo courtesy of Heinz North America.

Cold Supply Chain & Logistics

On the right track Refrigerated & Frozen Foods honors poultry, potato processors for green supply chain achievements. Last year saw Heinz North America increase rail shipping for forward product deployment.

t first glance The H.J. Heinz Co. and Butterball LLC appear as different as potatoes and poultry – and as opposite as the Northwest and Southeast. Yet both companies have reduced their supply chain carbon footprint and that common commitment brought them awards from Refrigerated & Frozen Foods. Recognizing food companies’ increased interest in corporate sustainability programs, R&FF took a “green” approach to its own annual award for supply chain performance. This spring, the magazine asked cold food processors and third-party operators to submit nominations, including examples of processors’ (1) supply chain network optimization, resulting in fewer over-the-road miles; (2) trailer-to-rail conversion, resulting in fewer over-the-road miles; (3)

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refrigerated truck/trailer enhancements; reducing fuel / or emissions and (4) product repackaging, resulting in more packages, cases and/or pallets shipped per truckload. Industry feedback brought two exceptionally strong nominations: one reflecting national turkey processor Butterball and its warehouse optimization efforts; and a transportationrelated play involving Heinz North America’s rail program for Ore-Ida potatoes. Speaking at the Food Logistics Forum this June in Denver, R&FF Editor Bob Garrison presented the magazine’s first “Sustainable Supply Chain” awards to Dan DiGrazio, Butterball’s director of logistics; and Matt Stalter, group leader, transportation for Heinz North America. The Food Logistics Forum (FLF) is

a cold food supply chain executives’ meeting co-sponsored by the American Frozen Food Institute and the Global Cold Chain Alliance. R&FF asked award winners to discuss their organizations’ year-over-year actions and achievements.

Optimize, reduce DiGrazio spoke about applying Butterball’s corporate sustainability program (“Do Business Right”) to supply chain activities. He noted that Butterball’s four-year-old green program focuses on simple themes of “reduce, reuse and recycle.” For the record, this Garner, N.C.-based company operates six turkey processing plants in Colorado, Missouri, Arkansas and North Carolina. In a post-convention interview, DiGrazio tells R&FF, “Our sustainability

Green Supply Chain Honoree: Butterball LLC PROFILE: This Garner, N.C.-based company is the nation’s leading retail, deli and foodservice turkey processor-supplier with six plants. ACTIONS: Butterball reviewed and optimized warehouse and transportation networks. It also moved 8 million pounds of over-the-road product to an intermodal program. Warehouse optimization plan resulted in a move to Wilmington, Ill., from Indianapolis. ACHIEVEMENTS: L-R: Butterball Director of Logistics Dan DiGrazio and RFF Editor Bob Garrison.

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CORPORATE OFFICERS ROBERT ENTENMANN · PRESIDENT LEO B. VOLLBRACHT · CHIEF EXECUTIVE KEVIN VOLLBRACHT · OPERATIONS MANAGER DENISE VOLLBRACHT · OFFICE MANAGER LENNY MUSKAT · SALES MANAGER

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Cold Supply Chain & Logistics team works to ‘do business right’ in a manner consistent with protecting the environment. We do this through energy conservation, feed and antibiotic conservation, pollution prevention, recycling programs, waste elimination and continual improvement of our environmental practices.” DiGrazio says logistics officials adopted three key initiatives following a 2010 first-quarter baseline study of Butterball’s supply chain network. “The analysis indicated that there was an opportunity to decrease cost and improve sustainability by locating closer to customers and our manufacturing plants,” says DiGrazio. “In part, this optimization program resulted in a fourth-quarter (2010) shift of our Midwest distribution center (north and west) from Indianapolis to Wilmington, Ill. Overall, our efforts cut distribution by about 355,000 miles; reduced diesel use by an estimated 71,000 gallons; and decreased CO2 emissions by 738 tons.” A second initiative involved a 2010 second-quarter upgrade to in-house transportation management. DiGrazio says new pilot optimizer programs suggested additional cuts in national over-the-road distribution. Butterball also addressed transportation and moved a portion of its distribution center truckload replenishment operations to an intermodal rail program. DiGrazio says this shifted 8 million pounds of turkey to rail cars – resulting in 9.5 percent fewer over-the-

road miles (equal to about 2.4 million), 480,000 fewer gallons of diesel and an estimated 4,987 fewer tons of CO2.

Rail advantage For the record, Heinz North America is the name behind a wide variety of products, such as Weight Watchers Smart Ones frozen entrees, Ore-Ida frozen potatoes and Bagel Bites frozen pizza snacks. In this case, R&FF recognized the Ore-Ida frozen potato business, which ships its frozen finished products on temperature-controlled railcars from Ontario, Ore., (near Idaho border) to regional, forward distribution centers nationwide. From there, Heinz works with third-party warehouse partners and over-the-road carriers to service retail customers. Stalter notes that – as long as three to four years ago – logistics group officials began scrutinizing inventory and production strategies to better utilize the company’s fleet of private, leased frozen railcars. By 2010, it was time to act and throughout the course of that year, Heinz increased the rail share of its forward-deployed volume by 20 percent. “The largest win for Heinz was utilization of the private, leased rail cars,” says Stalter. “In prior years, Heinz’s fleet was underutilized while trucks were flowing out the doors. Obviously, fleet utilization is a better use of transportation dollars than shipping

via truck. The journey culminated last year with one of the largest, year-overyear improvements.” Stalter says Heinz’s frozen potato rail tonnage increased by 33 percent and truck tonnage decreased by the same amount (about 38,000 tons), the company reduced diesel fuel consumption by 50 percent (about 630,000 gallons) and reduced its carbon dioxide emissions by 44 percent (about 6,400 tons of CO2). Heinz estimates that its shift in product deployment transportation took as many as 2,000 trucks off the road. “We did not eliminate all truck shipments,” notes Stalter. “There are still trucks on the road – albeit at a reduced rate.”

Call for 2012 nominations Know a cold food processor reducing its supply chain carbon footprint? Refrigerated & Frozen Foods already is thinking about next year’s award for a refrigerated or frozen food processorshipper. R&FF welcomes 2012 award nominations from processors as well as third-party logistics, warehousing and/or transportation suppliers. Call Editor Bob Garrison at (574) 935-3724 or email [email protected] for details.

Green Supply Chain Honoree: Heinz North America PROFILE: Part of H.J. Heinz Company, Heinz North America, Pittsburgh, Pa., processes and markets such items as Weight Watchers Smart Ones frozen entrees, Ore-Ida frozen potatoes and Bagel Bites frozen pizza snacks. ACTIONS: Heinz altered its forward distribution program and increased use of its private, leased rail cars by 20 percent ACHIEVEMENTS: Heinz boosted rail tonnage increased by 33 percent and truck tonnage decreased by the same amount (about 38,000 tons). It reduced diesel fuel consumption by 50 percent (about 630,000 gallons) and reduced carbon dioxide emissions by 44 percent (about 6,400 tons of CO2).

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L-R: RFF Editor Bob Garrison and Matt Stalter, group leader, transportation, Heinz North America.

www.RFFmag.com



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Cold Technology Showcase FOCUS ON: CONVEYORS, BELTING Less is better Dorner’s new eDrive™ Technically Advanced Power Transmission Line offers a 25 percent reduction in heat; a 30 percent reduction in weight; and a footprint that’s 15 percent smaller than conventional gear motors. Added together, eDrive provides customers with energy savings, safer installations, space savings and improved worker safety for precision belt conveyors. Designed with the latest advancements in aluminum-body gear head and motor technologies, eDrive comes with a two-year gear-head warranty, and is maintenance free. eDrive fits all Dorner industrial conveyor platforms (2200, 3200, 4100, 5200, 6200 and MPB). Gear heads and motors are equipped with both NEMA and IEC Flanges; motors range from 1/4 to 2 horsepower. – Dorner Manufacturing Corp. (800) 397-8664 / www.dornerconveyors.com

Exactly what you need Ashworth’s new ExactaStack self-stacking spiral belt is a drop-in replacement for standard and wide belt stackers. ExactaStack is available in all widths, tier heights, and mesh configurations for both spliced-in sections and complete belt replacements. As a drop-in replacement, no system drive modifications are required, and with every option available, Ashworth can deliver the right ExactaStack belt for your specific production needs. Ashworth factory service experts can provide a turn-key ExactaStack install, in addition to optimizing the stacker system and ensuring maximum throughput and capacity. – Ashworth Bros., Inc. (800) 682-4594 / www.ashworth.com

Quiet, easy to clean Key Technology introduces its newest vibratory conveyor, Iso-Glide(TM). An engineered modification of Key’s popular Iso-Flo® vibratory conveyor, Iso-Glide achieves a motion that resembles horizontal motion, which maximizes sanitation while offering gentle handling and quiet operation. Iso-Glide can perform a range of product handling and packaging distribution functions, including scale feed applications. It is ideal for many frozen food processors. Iso-Glide allows processors to experience the continuous selfcleaning benefits of horizontal motion conveying but on an Iso-Flo platform. Product virtually slides along the stainless steel conveyor bed, which prevents the buildup of coatings, oils, and seasonings. – Key Technology Inc. (509) 529-2161 / www.key.net 

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Cold Technology Showcase FOCUS ON: CONVEYORS, BELTING Creative solutions Keenline is in the business of creative solutions. When a nationally known dairy processor asked for end-of-the line help with its dairy enzyme product, Keenline developed a sanitary system that not only conveys the product but includes a Dairy 3A metal detector (designed by Keenline) and reject-eject function. The system (shown here) met our customer’s entire requirements and even performed beyond system specifications. Keenline is a leader in sanitary conveyor systems and solutions. – Keenline Conveyor High performance in a small footprint. The latest addition to the Systems SORTEX E range, the SORTEX E1D offers a high performance (920) 685-0365 / sort in a small footprint. It has been designed to bring the www.keenline.com benefits of larger sorters to smaller processors while delivering a high quality sorting in the freezing process. A combination of technologies and options allow for processors to tailor the sorter’s inspection system to their specific needs. It’s capable of inspecting product for discolored or misshaped product, subtle blemishes, FM or EVM, or any combination thereof. www.buhlergroup.com Buhler Sortex Inc. 209.983.8400 [email protected]

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

Safe Food. Clean Food.

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Ideal pallet layers The most recent addition to Intralox’s line of Activated Roller Belt™ (ARB™) equipment provides ultimate flexibility in the challenging palletizer infeed application. This unique solution for both new and retrofit palletizer applications features an electrically actuated switch that can handle up to 500 packs per minute in any orientation, while at the same time diverting to an infinite number of discharge points—all from a single input. Able to handle packs as small as 2” x 2” (51 mm x 51 mm), this ARB equipment solution provides the flexibility needed to adeptly handle today and tomorrow’s changing package types to create optimum palletizing patterns. – Intralox LLC (504) 733-0463 / www.intralox.com

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Cold Technology Showcase Save energy! Engineered with 70 percent open surface area, Wire Belt’s CompactGrid™ conveyor belt provides optimal performance in processes where liquid or air circulation are factors. CompactGrid’s flow-through capabilities will reduce the time required to heat up or cool down a product – and therefore reduce energy costs. Ask us about how CompactGrid belt dramatically reduced the consumption of nitrogen in a linear freezer at a major food processing plant. Moreover, when it replaced a plastic modular belt, CompactGrid increased cleaning efficiencies by an amazing 66 percent. – Wire Belt Company of America (603) 644-2500 / www.wirebelt.com 

Industry’s Most Reliable Team

Simplify hand packing Traditional hand-packing operations sacrifice weighing accuracy for good visual presentation. Now, to reduce product giveaway costs and increase versatility, Heat and Control has developed a Progressive Pack Conveyor integrated with a highly-accurate Ishida weigher for refrigerated or frozen applications. The Ishida weigher deposits each product charge into a diverting timing hopper centered over the Progressive Pack Conveyor. The conveyor has two flighted center belts to accept product charges, and independent variable speed packing conveyors on each side. Operators remove a product charge from the center flighted belt and arrange it in trays on the outer packing belts, which then carry the product trays to sealing equipment. – Heat and Control Inc. (510) 259-0500 / www.heatandcontrol.com

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Part of what makes Triangle the most trusted name in the industry is our service and training team. Looking to increase uptime, safety, and profits? Reduce overtime, costly service calls, changeover time, and material loss? Our PMMI certified trainers can help you do just that. With one of the largest and most experienced technical support staffs in the industry, we have the people to keep your machine running at peak performance...24/7/365. FOR MORE ABOUT TRIANGLE SERVICE, SCAN THIS QR CODE WITH YOUR SMARTPHONE

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Cold Technology Showcase FOCUS ON: FORM/FILL/SEAL EQUIPMENT Handles harsh environments

Lower film costs

Triangle’s X-Series bagging machine is available in three finishes including painted steel, stainless steel and USDA/3A models. Designed to perform in the harshest packaging environments, the X-Series bagger offers unmatched durability, sanitation and flexibility. Features include electro-polished stainless steel frames with continuous weldments to reduce vibration; stainless steel pivoting control box for 360-degree access; stainless steel pull-belt assemblies and anodized aluminum jaw carriers; and stainless steel, USDA-Certified forming tube assembly. – Triangle Package Machinery (800) 621-4170 / www.trianglepackage.com

Repak horizontal form/fill/seal packaging machines produce vacuum and modified-atmosphere packages from flexible and semi-rigid materials, as well as vacuum skin packages (VSP) and packages with formed-top webs. The Repak uses rapid air forming to maximize the distribution of film into critical areas such as corners. This allows package engineers to choose thinner forming films with cost savings of up to 20 percent. The Repak features a four-point lifting system on the forming and sealing dies to generate tremendous closing pressures. This ensures increased seal integrity and generates exceptional package reliability. – Reiser (781) 821-1290 / www.reiser.com 

MonitorTemperatures In Storage and InTransit The Escort iMiniPlus™ Data Logger is ideal for validating remote temperatures in cold chain transportation and storage. Each battery-powered logger offers a USB cable for downloading data. Internal and external sensors available.

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Escort iMiniPlus™ Temperature Logger

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Talk with our Application Engineers. Get a Free Quote. Quote 800-9 LOGGER (956-4437) www.DataLoggerInc.com

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Service. At 
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" machines are legendary for their reliability, they sometimes need service. Our plant runs day and night and when you need us we are there. Made in the USA. DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934 defranciscimachine.com [email protected] 321-952-6600

Many food processors are turning to HayssenSandiacre’s Novus Doy/Quad, a truly unique VFFS machine. It’s flexible enough to run both Quad Seal and Doy Packs with an easy changeover to high speed pillow bag production. All of these package styles can be created on this one system, by easy changeover of cassette: Doy Pack, Quad Pack, Flat Bottom Bag, Tucked/ Gusseted Bag and Pillow Bag. Learn more by visiting HayssenSandiacre September 26-28 at Pack Expo 2011, Booth #C-500 at the Las Vegas Convention Center. – HayssenSandiacre (864) 486-4000 / www.hayssensandiacre.com

Cleanable, accessible WeighPack’s XPdius Elite series of vertical form, fill, seal baggers address demand for cleanability, accessibility and serviceability – as well as the highest productivity with running speeds up to 100 cpm. Ergonomically designed, XPdius Elite baggers open on both sides for effortless access to all components inside the frame. Tool-less, quick removal of change parts reduces changeover and servicing time. With an open concept, the frame has been reduced and does not encompass the jaws on the XPdius Elite models; jaws are more accessible and this reduces the area for product to collect – making cleaning easier and quicker. Electronics and pneumatics also have been completely separated into designated panels for easy servicing. – WeighPack Systems Inc. (888) 934-4472 / www.weighpack.com

Many apps, fast changeover ROVEMA’s new VBMC-400 Continuous Motion Bagger is the ideal solution for efficient frozen food packaging. The VBMC-400 features stainless steel housing and a NEMA 4X electrical cabinet for harsh production environments. The two-axis, servo-controlled cross-seal motion with continuous motion film feeding results in production reliability and high performance. The unit can produce pillow-style packages with a flat bag width of 400mm. Moreover, it’s flexible to handle a wide variety of packaging materials with quick and simple changeovers. – ROVEMA Packaging Machines, LP (770) 513-9604 / www.rovema.com

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Cold Technology Showcase Retail, shelf-ready packaging With so many retail-ready and shelf-ready packaging concepts coming to market, Delkor elected to dedicate its PACK EXPO Las Vegas exhibit to this theme. In the past year, Delkor has designed as many as eight new machines for various retail-ready or shelf-ready packaging applications. Process and packaging engineers are invited to see them highlighted at Delkor’s PACK EXPO exhibit, No. C-4045. Ask us about Delkor’s new Trayfecta Servo Former, the best precision former on the market for corrugated or paperboard. – Delkor Systems (800) 328-5558 / www.delkorsystems.com

New cold panel partners CSI Sales Group, a single-source provider of insulated and mechanical products for low-temperature facilities, has begun offering insulated metal panels from 35-year manufacturer MCBI. “Realizing that energy codes and regulations were becoming more stringent and a building’s long-term envelope performance was becoming more critical, we retooled our Jackson, Miss., plant and unveiled the most advanced insulated metal panel line in the country,” says Wayne Dickinson, MBCI president. Officials note that CSI has 11 sales nationwide offices. CSI will represent MBCI’s new Eco-ficient insulated metal panels. – MBCI (877) 713-6224 / www.mbci.com/coldstorage

rigeration Ref Improve your food-processing facility's design. engineering architecture process optimization

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Refrigerated & Frozen Foods SEPTEMBER 2011 31

Cold Technology Showcase Tabletop filler, depositor Hinds-Bock’s SP-16T Tabletop Filler/ Depositor is simple to operate and can be disassembled in minutes for cleaning without tools. Increase production while decreasing labor costs. Accurate and precise filling reduces cost and product waste. The SP-16T is ideal for a wide variety of flowable or semi-flowable products like cake and muffin batter, jams & jellies, dips and spreads, cream topping, salsa, chili and more. SP-16T features include accurate piston filling, positive shut-off spouts for clean filling, automatic cycling control options, and 2-oz to 12-oz fill size options. Air requirement is 80 psi / 6 SCFM. – Hinds-Bock Corp. (877) 292-5715 / www.hinds-bock.com

Enhanced analyzer For over 30 years the NelsonJameson M926 Chloride Analyzer has accurately and precisely measured salt content of food and dairy products. Now this popular instrument comes with several enhancements. Calibrations are factory-set to ensure accuracy over a wide test range and prevent unauthorized adjustments. Visual prompting appears on a LED-backlit display. Switches embedded in a metal frame – and sealed under a vinyl shield – permit rugged use and easy cleaning. An external transformer protects against surges in power supplies and cooler operation. USB and RS232 data ports allow electronic capture and processing of results. – Nelson-Jameson Inc. (800) 826-8302 / www. nelsonjameson.com

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Cover, inside photos by Ross Van Pelt, RVP Photography

CEO Bill Toler (right) and AdvancePierre Foods officials lead a new $1.5 billion business from Cincinnati.

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et’s face it: transformational, step change is not easy. But it can help to have someone coach you through the process. It starts with an imagined view of a better future and perhaps a phrase, such as, “Let’s paint a picture...” Then there are times when you literally need to make it real. For example, a Dallas hotel hosted the first face-to-face meeting of 150 executives from Pierre Foods, Advance Food Co. and Advance Brands LLC – shortly after the three companies merged in July 2010. The first night involved an ice breaker with paints, paint brushes and even painting smocks. A leader divided the group of 150 into teams of eight, including one member from each legacy business. Each team then followed directions to paint a small, 30-inch-by-30-inch canvas square. When the group assembled the next morning, they found their 24 individual squares now joined as a horizontal, wall unit stretching 20 feet wide by 7 feet tall. It had the company’s new name AdvancePierre Foods, as well as its new logo, legacy company names and brand logos. “We wanted a way to start this business meeting with something that would get people talking and interacting immediately,” 34

Refrigerated & Frozen Foods SEPTEMBER 2011

says CEO Bill Toler. “We had designed the new company’s logo but nobody had seen it. It wasn’t until the following morning that we had a dramatic revealing on stage as a complete piece of artwork that everyone had contributed to. The ice breaker also fit our catch phrase for that meeting, which was ‘better together.’” That’s how AdvancePierre Foods (APF) began just last year as a $1 billion-plus company comprised of three competitive-butcomplementary businesses serving foodservice operators and distributors (Advance Food’s strength); clubs, schools, military and convenience stores and vending (Pierre Foods’ strength); and grocery retailers (Advance Brands’ strength). Against the broader meat and poultry industry landscape, APF is a distinct player specializing in value-added, further prepared frozen meat and poultry, hamburgers, sandwiches and Philly steaks. Behind the scenes, APF’s three new divisions share a functional support network of marketing, R&D, operations, supply chain, I.T. and finance. It’s a structure orchestrated by Toler, a 25-year CPG industry veteran; and Los Angeles equity investor Oaktree Capital Management LLC. Toler and Oaktree led Pierre out of bankruptcy after they bought the business in 2008. Toler recast Pierre’s operations structure (rationalizing SKUs, adjusting prices, emphasizing efficiency). Since then, he also has staffed both Pierre and APF with top internal and outside talent, including veterans from CPG and restaurant companies. Toler says APF’s three-pronged business strategy involves . . . … organic growth. Toler says the “magic” in APF’s corporate www.RFFmag.com

[ Cover Story ]

Sign of the times Acquisitions, product and process innovation help newly formed AdvancePierre Foods make a name for itself in frozen prepared meats, sandwiches. By Bob Garrison

model relies on salespeople taking each legacy business’ products into new channels. “Besides straight-forward sales and profit, I look to see if we’re cross-selling products into other channels – and that is happening,” he says. “For example, our [Advance] bulk meat sales already are up in c-store and vending outlets and [Pierre] sandwich sales are up in both foodservice and retail.” … acquisitions. Things went so well at APF that it was only 11 months (June 2011) before it acquired Barber Foods, a retail frozen stuffed chicken entree and specialties processor in Portland, Maine (see “Welcome to the family,” p. 41). “Barber immediately becomes our No. 1 retail brand,” says Toler. “Meanwhile, we can take [the retail line] further into West and Midwest markets and we can test our cross-selling model. We believe we can sell Barber products into other sectors, such as convenience stores and foodservice.” Toler says APF and Oaktree hope to make one or two more acquisitions during the next 12 months. He says ideal candidates are small- to mid-size companies (any channel) with value-added frozen proteins and/or sandwiches and entrees. … innovation. Just 15 months old, APF already has demonstrated its product development and packaging capabilities everywhere from Smart Picks, a complete new line meeting school foodservice nutrition guidelines; to new frozen private label retail sandwiches. Here, Toler relies on senior packaged food and restaurant chain veterans Lisa Frick, senior vice president of marketing and product development; and Bernie Panchot, vice president of product development. Both women are products of larger publicly traded food companies (packaged foods, restaurant chains) and say APF has a multi-dimensional, nimble organization to drive research and www.RFFmag.com

results. For starters, Frick says corporate marketing uses a matrix structure whereby marketers’ roles and responsibilities are aligned with strategic short-term and/or long-term initiatives supporting each unit. Marketers also are organized by channels and by products (proteins, sandwiches). Still more are involved in original consumer insights research. “We have some pretty sophisticated customers who also are some of the food industry’s largest operators,” says Frick. “I’m proud of how our teams have managed to stay nimble and responsive while keeping an eye on hundreds of projects. We also have visibility to see projects across the company to maximize the potential of these projects and balance our day-to-day work with building a three-year innovation pipeline that includes new ‘platform’ ideas that fit across our entire business. Given that we are also spending a lot of time right now on company integration activities, I think we’re just scratching the surface on what our innovation pipeline can produce.” Panchot agrees. “I think there is a magic to what we can accomplish by applying learning and driving insights through the organization with passion. We brought together a diverse range of skill sets and we already have consumer insights research and a solid process where our sales teams are aligned with customers. And from meats to bakery, we have technical team members aligned with manufacturing so we’re prepared to deliver from beginning to end. No grass grows under our feet.” Continued on page 41. Refrigerated & Frozen Foods SEPTEMBER 2011 35

Frozen Food Processor Of The Year

AdvancePierre Foods

Better together AdvancePierre Foodservice Division unifies around customer service, new products.

I

t’s where educational reform meets educational foodservice. American philosopher and educational reformer John Dewey once said, “Arriving at one goal is the starting point to another.” Perhaps there’s no better way to describe life at AdvancePierre Foods’ (APF) Foodservice Division. To meet new federal school foodservice nutrition objectives, researchers at Cincinnati’s Pierre Foods worked a full year to reformulate as many as 60 frozen center-of-the-plate proteins, sandwiches and entrees. By July 2010, Pierre completed that work and unveiled Smart Picks, a broad, betterfor-you line with foods containing more fiber, protein and whole grains; reduced sodium and fat; and no hydrogenated oils or trans fats. Of course, it also was in July 2010 that Pierre merged with foodservice competitor Advance Food Company and its sister retail business, Advanced Brands LLC. Shortly afterward, APF President Bill Toler came up with a new goal for Mark Allen, who had just come over from Advance to become APF’s new Foodservice Division president. As APF’s largest business – supplying more than 2,200 SKUs across all foodservice segments –Toler wanted APF Foodservice to stay in the spotlight and simplify customer’s lives. The new division would offer multi-unit chains and distributors the benefit of one order, one delivery and one invoice. APF says it met that goal at the beginning of June 2011. “It’s hard to bring cultures together when they used to be somewhat competitive,” admits Toler. “That ‘one order, one invoice’ objective rallied people around a key business goal and kept the focus there – instead of on a certain person or company. It was a matter of realizing, ‘We’re all on the same team now.’ We all learned to work across functional departments and although it was challenging, it was very rewarding.” Allen, a member of one of the co-founding families, smiles when asked about APF’s first full year. “We faced some distractions due to the merger, shifted our customers to two distribution centers and we had to raise prices a few times,” he says. “Yet our group still found a way to increase sales and – with the exception of just a couple of people – the entire group is intact. I’m very proud.” While operations, supply chain and sales focused on “one

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Refrigerated & Frozen Foods SEPTEMBER 2011

Better-for-you Smart Picks items expand in foodservice after school debut.

order” simplicity, Allen cross-trained all foodservice salespeople on both companies’ complete product lines. Today, with newly acquired Barber Foods added to the mix, APF says its sales representatives now offer customers and distributors a single, comprehensive presentation across five frozen food categories: Philly steaks, breaded meats, fully cooked burgers, sandwiches and stuffed chicken breast entrees. Allen says that during a period of unprecedented beef price increases, APF is working harder to offer “best value solutions” and fit operators’ price-point needs with everything from chopped-and-formed items to premium offerings. He notes, meanwhile, that all APF items are value-added and further processed. Value-added new products are expanding beyond the school cafeteria trays, as well. Since Smart Picks’ school foodservice debut, APF has extended the better-for-you line to restaurants as well as hospitals, nursing homes, workplace and college cafeterias. Still more new offerings include a line of Mercato Grille Panini Sandwiches (where varieties include Chicken Parmesan, Asiago Chicken, and Three Cheese & Tomato) and most recently, two new Simply Grilled Chicken Dippers and Simply Grilled Turkey Dippers. Officials say these items meet school foodservice directors’ interest in proteins with minimal seasoning that can be used as a simple base for wraps and salads – or be paired with a dipping sauce. Behind the scenes, APF is just as active developing custom products. “I’m particularly proud of a turkey burger we created for a mid-size, regional restaurant chain,” notes Bernie Panchot, APF’s vice president of product development. “Chain executives brought it up – saying that this would be the right time and right place for their restaurants because consumers are more focused on nutrition. It’s become a market niche for them and us and they since have rolled it out to multiple locations.”

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AdvancePierre Foods ™

Frozen Food Processor of the Year Congratulations from JBT FoodTech

Your JBT FoodTech Solutions Team

Frozen Food Processor Of The Year

AdvancePierre Foods

More in store AdvancePierre Brands Division adds Barber, eyes more products, customer service.

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ometimes a new job isn’t everything you expect it to be. Actually, sometimes it’s better. Just ask Chris Kiser. When Kiser joined AdvancePierre Foods (APF) last October as Brands Division president, APF’s frozen National retail line now spans more than 500 branded, private label items. retail business had a broad line of frozen fully cooked prepared meats (beef, chicken, pork), Philly as breakfast, lunch and snacking to address these needs. steaks, sandwiches and appetizers. The group also was just beginning to supply private label frozen products and We’ve been watching the category grow and I believe we’ve helped it to hit a tipping point. It’s become a meaningful busisandwiches to mainstream retailers. ness and we’ve been busy supporting it with new products This June, just nine months later, APF bought Barber and packaging.” Foods, a 56-year-old processor of retail premium frozen Kiser says APF’s depth of consumer insight influenced the stuffed chicken entrees and other chicken specialties (see company’s initial “core four” private label offerings: cheese“Welcome to the family,” p. 41). burgers, bacon cheeseburgers, breaded chicken sandwiches “Our business was a certain size through May of this and spicy chicken sandwiches. This fall brings a second wave year. Just a month later – with the announcement – we of complementary, on-trend items such as mini’s, flatbreads, instantly grew by about 40 percent which added immediate paninis and expanded breakfast options. scale to our entire retail platform,” says Kiser. “Barber is “We’re seeing these taste trends come to life in restaunow our largest retail brand and gives us a much larger marrants,” says Kiser. “Because of our manufacturing capability ket presence.” there’s really little we can’t do when it comes to putting these Understandably, Kiser will have much more to discuss popular items into a retail footprint.” with retail buyers this fall at the National Frozen & Of course APF has more news to share with retail partRefrigerated Foods Convention and Private Label ners. Manufacturers Association’s (PLMA) trade show. APF now is For starters, the expanded Brands Division sales force that a sizeable supplier with more than 500 SKUs ranging from now includes Barber will give APF an enhanced portfolio of frozen prepared meats, Philly steaks, stuffed chicken breasts, options for retailers: Barber, Fast Fixin’, Fast Classics, Pierre hand-held entrees and appetizers. On the Go PB Jamwich and Steak-EZE. Kiser believes the “We’re big enough to matter but extremely flexible,” says new APF can help the Barber brand achieve wider and deeper Kiser. “We have diverse production facilities to draw upon sales distribution in Midwest and western markets (Barber is and that gives us incredible capability to create unique and on-trend products. More importantly, we have a business unit strongest in the Northeast). Meanwhile, APF and Barber product developers can partner on value-added across fully structure and a corporate team mindset that lets us move cooked and hand held via differentiated line extensions. quickly to take advantage of opportunities. This approach Last but not least, Kiser says he is excited to bring customallows us to commercialize good ideas at speeds that are ers more than just new products. He says APF is mobilizing to unprecedented.” offer customers improved sales solutions including more conSpeaking of speed, Kiser says APF’s frozen retail private sumer insights, and tools that simplify purchasing. label sandwich business is gathering momentum. “Our deep heritage in foodservice helps us get in front of “This is an emerging new segment within the freezercase,” eating trends,” notes Kiser. “Meanwhile, we also have he says. “Retailers realize that consumers want more handheld options beyond what has been available. They increasachieved a level of scale now that allows us to make targeted ingly want offerings geared around various meal-times, such investments in research.”

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Refrigerated & Frozen Foods SEPTEMBER 2011

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Frozen Food Processor Of The Year

AdvancePierre Foods

Right place. Right time. New products, customer support help AdvancePierre Convenience Division drive c-store, vending sales.

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onsumer trends favor your product line? That’s convenient. Speaking of convenience, foodservice market researcher Technomic found consumers’ grab-and-go lifestyles accounted for approximately $10.6 billion in prepared food sales from convenience stores during 2010. The Chicago researcher predicts c-store prepared foods will enjoy 2.5 percent nominal growth through 2013. Technomic also says hand-held entrées will drive that growth and account for up to 38 percent of total foodservice sales. Considering that frozen hand-held sandwiches make up most of the 300 items in AdvancePierre Foods’ (APF) Convenience Division, those trend lines are welcome news to Convenience President Tony Schroder. A 20-year-plus company veteran (coming up through Pierre Foods’ operations and sales groups), Schroder believes APF clearly is in the right place at the right time. “It’s no secret that breakfast sandwiches are one of the biggest trends at foodservice and that’s equally true for our customers,” he says. “Convenience stores sell lots of coffee and breakfast sandwiches match up well. Many operators want to offer a better value with a hot breakfast.” Schroder takes a broader view and continues, “We’ve grown from being an entry-level player to the biggest supplier of frozen sandwiches for both channels – convenience stores and vending,” he says. “And although we’ve become the leader in the field, we still behave like a small company to take care of customers,” he says. “We’re flexible and react to their needs.” What do c-store and vending customers want? Schroder says APF offers custom field research to help customers improve in-store sales and operations. Meanwhile, dedicated division personnel also assist with custom new products, packaging and promotional support. Case in point. Schroder says APF needed just 10 weeks to develop a line of private label frozen breakfast sandwiches

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Refrigerated & Frozen Foods SEPTEMBER 2011

Spice of life. New items target on-trend tastes, formats.

and packaging for a Southeast convenience store chain. That speed enabled the chain to optimize its own in-store and billboard marketing programs. In another instance, Schroder says APF gave a Midwest c-store chain a complete private label breakfast and lunch program – custom formulations and packaging included – in just 12 weeks. Custom work aside, APF product developers are keeping c-store and vending customers on trend. Schroder says APF’s ongoing research involves spicier offerings (Big Az Kickin’ Jalapeno Cheeseburger), mini sandwiches and even artisan melts (Pierre Panini Style Melts). He says there are more technologies at work behind the scenes – such as dual-ovenable butcher wrap packaging, controlled-melt cheeses and better buns and ingredients that hold up in display warmers. Yet another new offering is APF’s complimentary “FEAST” or “Field Execution And Store Training” program. Here, an APF field expert will consult with a customer, audit a percentage of that customer’s stores and then provide a summary foodservice report complete with pictures and recommendations. “Our biggest opportunity involves helping customers sell more products and increase turns per day,” says Schroder. “We might find that there’s not enough product in a warmer during peak hours. Stores also may not be fully using our point-of-purchase materials or headers to grab attention . . . No matter what, we’re happy to go out and help provide store-level training. In the end, this also helps us tweak and improve our merchandising, products and warming technologies.” APF is equally busy in vending. In fact, the company sampled several new SKUs at the National Automatic Merchandisers Association convention in Chicago. Among them: a co-branded Double Deck Cheeseburger from Big Boy restaurants; Pierre Minis (nearly a dozen varieties), the Big AZ Kicken Jalapeno Cheeseburger and Pierre Panini Style Melts.

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Frozen Food Processor Of The Year

AdvancePierre Foods

Continued from page 35.

),&,(17

Family-owned Barber Foods extends AdvancePierre’s retail reach.

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Welcome to the family

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lready a leader in frozen, prepared beef and poultry products distributed at foodservice, AdvancePierre Foods (APF) acquired a complementary retail business this June. It welcomed Barber Foods, a Portland, Me., processor of frozen stuffed chicken entrées and specialty items for retail grocery and club stores. Terms were not disclosed. “By adding the Barber brand to our existing line of valueadded poultry offerings sold under the Fast Fixin’ and Fast Classics trademarks, we have a whole new avenue for retail growth,” said Chris Kiser, president of AdvancePierre’s Brands Division. “The enhanced portfolio of products strengthens our leadership position in this key category.” For the record, Barber produces more than 300 frozen raw and fully cooked items including stuffed chicken breasts, ranging from Chicken Cordon Bleu and Broccoli & Cheese Stuffed Chicken to Chicken Stuffed with Scallops and Lobster. The company also processes frozen chicken nuggets, chicken fingers, and chicken fillets. Officials say the Barber brand has a “significant” presence in retail grocery, club and foodservice channels, particularly along the East Coast and in Canada. Barber’s Portland plant has four production lines and the company employs more than 500 area residents. “As the food industry continues to consolidate and bigger players emerge, it was the right time for Barber Foods to join forces with a growing industry leader like AdvancePierre,” said David Barber, company president and son of the founder of Barber Foods. “Our products are a terrific compliment to their existing line, and we share similar philosophies about our priorities of food safety, quality, service and productivity leading to growth. It’s a great fit.” Officials say David Barber will serve on APF’s executive team.

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Refrigerated & Frozen Foods SEPTEMBER 2011 41

AdvancePierre Foods

Cold Plant Operations

Fired up AdvancePierre Foods aims for operational excellence in every

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t’s a weekday afternoon and Mike Zelkind is a man on the move. Literally. One hot summer July day finds AdvancePierre’s (APF) senior vice president of operations on a four-hour, 200-mile-plus journey from Cincinnati headed northeast on Interstate 71 to an APF frozen sandwich plant in Amherst, Ohio, near Cleveland. Accordingly, Zelkind has plenty of time to talk to Refrigerated & Frozen Foods about life heating up at a company that’s also on the move. “I’m incredibly proud of this team’s work,” says One of AdvancePierre’s largest facilities, Cincinnati processes beef, Zelkind, who has 20 years of food plant operating and poultry and pork products for all channels. supply chain experience from posts at CPG companies, Ready to grow again? Not even one year old, APF a leading corporate consultant and a retailer. “I’ve announced this June that it purchased frozen stuffed chicken worked in lots of operations environments. Yet I have never entrée and specialties processor Barber Foods in Portland, seen the speed with which our teams have produced and Maine. With that, APF now employs approximately 4,500 adopted a new culture. I’m amazed at the effort.” people and its 11 plants produce more than 3,000 types of Zelkind joined the former Pierre Foods in January 2009, packaged sandwiches, fully cooked chicken and beef prodshortly after APF President Bill Toler and Oaktree Capital ucts, Philly-style steaks, stuffed chicken breasts and bakery Management brought the frozen sandwich business out of products. bankruptcy. Toler says Pierre’s quick turnaround largely Speaking of effort, Zelkind quickly acknowledges that APF involved operations as he and Zelkind cut Pierre’s product has much more to do involving capital projects, logistics and line, introduced new productivity measures and pruned productivity initiatives and software systems coordination. Pierre’s operations network (closing an Atlanta-area plant). Nevertheless, he sees his group making progress where it Then it was time to go big. Really big. In July 2010, Pierre counts the most: corporate culture. merged with Advance Food Company and Advance Brands “That’s the biggest challenge,” he says. “It’s a matter of and almost tripled the operations network to 11 processing merging different cultures, building trust, establishing the plants from Enid, Okla., to Claremont, N.C. This time, Toler right relationships and acting as a high performance team. It’s challenged Zelkind and his team to quickly coordinate sales with inventory demand, operations, supply chain and custom- starting to feel like we’re getting there and I’m grateful for a er service. The goal? APF wanted to give its largest customers company that supports us. It’s important to communicate the (those in foodservice, c-stores and vending) the simplicity of same message from the top and at our recent national manplacing just one order, receiving one shipment and handling agement meeting, operations and supply chain had a seat at one invoice. Zelkind says he and his team established three the table.” national distribution and product mixing centers and comWhen it’s come to communicating a singular message pleted the entire assignment in six months’ time. within operations, Zelkind says APF has embraced and

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www.RFFmag.com

Photos by Ross Van Pelt / RVP Photography

growth stage.

AdvancePierre Foods

Cold Plant Operations AdvancePierre operations, distribution Orange City, IA ✪✪

Portland, ME ✪

Amherst, OH ✪

Cincinnati, OH (HQ) ✪✪ Claremont, NC ✪ Easley, SC ✪ Anaheim, CA ✪

Enid, OK ✪✪✪✪✪✪

✪ Manufacturing - Fully Cooked ✪ Manufacturing - Raw shared each legacy company’s “best-of-breed” activities. Meanwhile, APF expects each site to take up the same core values. “We follow a simple philosophy and there are two constant priorities,” says Zelkind. “One is food safety and food quality and the other involves employee safety. We discuss these issues at every meeting. If we can’t guarantee good, wholesome food, if we can’t guarantee a safe work environment for our people, we don’t have the right to be here. “We also have established a productivity program because we have to improve each year to help buffer inflation in the meat industry,” Zelkind adds. “We focus, first, on our top priorities but a competitive cost structure is how we win.” To that end, APF has a companywide operations business improvement team charged with identifying and sharing best practices; and inviting and addressing employees’ productivity suggestions. “We want at least half of our in-plant activities to be focused on product improvements – not just cost-cutting measures,” notes Zelkind. “Meanwhile, I think it helps make your culture cohesive when you look at the same metrics and

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✪ Assembly/Bakery Facilities ✪ Distribution you solve problems – involving everything from purchasing to transportation – as a team.” For that matter, APF team members already have been quite busy addressing … … capital projects. Zelkind credits financial partner Oaktree Capital for funding a wide range of capital projects during the past two years. These projects are increasing APF’s sandwichmaking capacity, automating packaging lines and improving process controls. “We’ve found a nice sweet spot and are automating where we can, depending on the format,” notes Zelkind. “On the other hand, flexibility is more important because we work closely to customize and commercialize so many items for our customers.” Some of APF’s largest projects have involved a new bakery and distribution center in Claremont, N.C.; expansion for increased sandwich capacity in Amherst, Ohio (near Cleveland); and expansion at APF’s Easley, S.C., plant for more sandwich and bakery foods production. … systems and supply chain. “We have a unique niche,” Zelkind adds. “We’re not the largest processor and not the

Refrigerated & Frozen Foods SEPTEMBER 2011 43

AdvancePierre Foods

Photos by Ross Van Pelt / RVP Photography

Cold Plant Operations

Formed pork patties en route to cooking at AdvancePierre’s Cincinnati plant.

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Refrigerated & Frozen Foods SEPTEMBER 2011

smallest. Meanwhile, we’ve laid out different market strategies – each with clear channel focus and a matrix involving our products… Behind it all, we have different supply chains to support our business,” he continues. “And, different customers have different needs. Some want lowest cost while others need product tomorrow.” Talk about differences. Zelkind notes that each of APF’s four legacy businesses (including Barber) had different enterprise resources planning (ERP) software. As a result, APF is shifting to a single ERP platform and added common demand management, forecasting, deployment and transportation management programs. “I’m proud of how we created a distribution network and used demand management to give our foodservice customers the simplicity of one order and one invoice,” says Zelkind. “Moreover, we did it in just six months with virtually no service interruptions. “We saw the Barber acquisition coming so we did not execute a similar program on the retail side – but that’s coming,” he continues. “Most of all, it’s been great to see all of our people merge their skills and talents together. We’re truly operating like one national company.”

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Cold Partners in Progress

Reduce labor. Save product. An automatic bagger and scale system helps Canada’s Desco accurately package more chicken with less labor.

roduct give-aways. An individual hand-made touch. These attributes are great when you’re talking about new products and marketing promotions – but they have no place on the production room floor. One company that can attest to this is Desco, a Boisbiand, Quebec, leader in further-processed fresh and frozen poultry and deli meats. This 31-year-old business supplies more than 100 fresh and frozen branded and private label items to retailers and foodservice distributors throughout Canada and the eastern United States. Manuel Nunes manages Desco’s poultry plant, which prepares boneless IQF and fresh chicken breasts in 2.5-lb. and 11-lb. pillow bags, respectively. Although Desco’s products were ideal for customers, the behind-the-scenes process used to be less than ideal, admits Nunes. “We were doing everything by hand,” he says. “We weighed product by hand and filled bags by hand . . . Our weights were not very accurate and we were seeing a lot of product giveaway. We also employed as many as 12 to 14 people on the line.” That was before Desco discovered Chicago’s Triangle Package Machinery Company. After meeting Triangle representative Ed MacPhee last year, Nunes decided to purchase and install a Triangle B35 intermittent-motion VFFS Bagger and Model A-612 Combination Weigher. A predecessor to its current X-Series, Triangle says the B-Series Bagger includes many hallmark features such as quick, no-tool forming tube change, patented 16-sided forming tube, open design for easy maintenance, easy-touch programmable changeovers and virtually maintenance free, cross-seal jaw drive. Officials say the A-612 Scale is part of Triangle’s family of Selectacom computer weighers. This in-line scale normally mounts directly over a Triangle bagger, features 12 selection buckets and runs at speeds of up to 135 weighments per minute. But due to ceiling height constraints, Triangle was able to place the scale behind the bagger, feeding weighments via a flighted belt conveyor. Nunes has been impressed by the results. “Our goals were accuracy and speed and the equipment has exceeded our expectations,” he says. “Weights are now very accurate and production is significantly faster . . . In fact, I call the Triangle bagger ‘my Ferrari’ because that’s how fast it can go.” No less important, the poultry bagging line now requires just four employees instead of 12 to 14. “Our speed guarantee was 20 bags per minute for 11-lb. bags with an accuracy guarantee of plus 9 grams (weight variance). Actual production accuracy at 20 per minute has come in even better at plus 4 to 5 grams,” notes MacPhee. “Gas flushing also was critical. We had to guarantee residual oxygen content of less than 2 percent and we’ve met that objective.”

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Canadian poultry processor Desco uses a Triangle A-612 Scale and B35 VFFS Bagger (predecessor to the new X-Series) to more accurately and quickly pack fresh and frozen poultry.

Thanks in part to increased production speeds and reduced labor associated with the Triangle system, Desco reported as much as a 250 percent gain in line productivity. Speaking of labor, Nunes has been equally pleased with the Triangle machine’s uptime. “We installed the system and a service technician came in to show us how to run it. It was not very complicated and we haven’t even needed follow-up service.” Nunes notes that Desco technicians know they can contact Triangle and take care of any problem quickly and easily. “A phone call will do the job,” he says. Chances are, the next time Nunes calls MacPhee, it will be to place another order. “This was our first time to work with a Triangle and it’s been a nice machine,” says Nunes. “If we decide to expand in the future – and need another bagger – it will definitely be a Triangle.” – Triangle Package Machinery Company (800) 621-4170 / www.trianglepackage.com Refrigerated & Frozen Foods SEPTEMBER 2011 45

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Ashworth Bros., Inc.

Exopack

Ashworth Bros., Inc. - Innovating for Efficiency Marked by more patents in the industry than any other belting manufacturer, Ashworth Bros., Inc. continues innovating conveyor belting technologies that increase efficiency for food processing industries. Ashworth is the only belting manufacturer that utilizes both metals and plastics to engineer conveyor belts that increase throughput and minimize downtime for the most demanding applications. Omni-Pro® 075, 100, 120 & 150 Belts minimize cage bar wear, maintenance costs and downtime in the most demanding high-tension spiral applications. Capable of withstanding tensions up to 400lbs. and rated for 100,000 cycles, versus competitor ratings of only 50,000 cycles, Omni-Pro delivers unmatched strength and reliability. The patent pending 360º “zero-tension” welds increase strength while the patented coining process prevents break-in wear, reduces belt elongation and increases belt life. The patented “protrusion leg” design eliminates welds from contacting spiral cage bars, enabling the belt to run smoother with less system wear. Advantage Belts are the industry’s only plastic spiral conveyor belts that are USDA accepted. Designed on the strength of stainless steel rods, Advantage belts are guaranteed not to sag. The plastic mesh offers the greatest open area, increasing airflow and delivering the shortest dwell times. Advantage belts withstand tensions up to 300 lbs for 100,000 cycles, making it the industry’s strongest plastic spiral belt. Cleatrac® belts travel around the smallest nose bar diameters in the industry (down to 0.20 inch) to accurately transfer small products, minimize damage and improve profits. Ashworth guarantees positive sprocket engagement with the Cleatrac® Belt & Sprocket System, ensuring precise product conveyance. The balance weave design is extremely durable and available in a variety of mesh configurations to provide proper product support and airflow for a wide range of applications. Standard widths are stocked for immediate delivery. Ashworth Factory Service offers a full range of engineering and maintenance services for stacker and lotension spiral conveyors, including trouble-shooting, belt installation, system upgrades, refurbishment, and relocation. On-call 24/7/365, Ashworth Factory Service Experts provide you peace of mind with decades of experience, quality workmanship, and comprehensive belting support.

Managing eighteen production facilities strategically positioned across North America and the United Kingdom, as well as a global network of alliance partners, Exopack is an established leader in the development, manufacture, and sourcing of flexible packaging and coatings solutions for various consumer and industrial enduse markets. PolarFLEX™ packaging from Exopack delivers the strength, convenience, and graphic appeal necessary to keep your product at the forefront of today’s competitive frozen food market, while producing positive bottom-line results. A perfect package for frozen items such as meats, French fries, and prepared meals, PolarFLEX utilizes a proprietary film blend that offers great puncture resistance, machineability and a wide seal range for hostile frozen environments. It is also a superior film for down-gauge applications.

Contact: Ashworth Bros., Inc. 450 Armour Dale Winchester, VA 22601 Phone: 540.662.3494 or 800.682.4594 Fax: 540.662.3150 or 800.532.1730 E-mail: [email protected] Website: www.ashworth.com

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Refrigerated & Frozen Foods SEPTEMBER 2011

Key Attributes s"AGS POUCHES ANDROLLSTOCKCUSTOMERENGINEEREDFOREXTREMELOW temperature storage (performance tested below -400 F). s-ATERIALSPROVENTOINCREASEMACHINEABILITYANDFILLINGLINESPEEDS (including VFFS and HFFS). s#OATINGSANDBARRIERSTOPROVIDEPROTECTIONDURINGDISTRIBUTIONAND storage. s%ASYOPENCLOSURESYSTEMS s COLORPROCESSPRINTING INCLUDINGAVAILABLE(IGH$EFINITIONGRAPHIC options. s&OOD3AFETYAND(!##0#ERTIFIEDMANUFACTURING

Contact: Exopack Tom Grabowski, Marketing Director, Consumer Food & Specialty Products Address: 3070 Southport Road, Spartanburg, SC 29302 Phone: (877) 447-3539 Fax: (864) 596-7116 URL: www.exopack.com Booth Number: 5831 E-mail address: [email protected] See us at PACK EXPO Las Vegas Booth #5831

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW PREVIEWS SPECIAL ADVERTISING SECTION

Intralox, L.L.C.

Intralox, L.L.C. is a global provider of conveyance solutions and services designed to optimize product handling systems for manufacturers worldwide. The most recent addition to Intralox’s line of Activated Roller Belt™ (ARB™) equipment provides ultimate flexibility in the challenging palletizer infeed application. This unique solution for both new and retrofit palletizer applications features an electrically actuated switch that can handle up to 500 packs per minute in any orientation, while at the same time diverting to an infinite number of discharge points—all from a single input. Able to handle packs as small as 2” x 2” (51 mm x 51 mm), this ARB equipment solution provides the flexibility needed to adeptly handle today and tomorrow’s changing package types to create optimum palletizing patterns. Whether you need to reduce overall system costs, save floor space, or reduce system controls and complexity, consult Intralox early on in your planning process. We’ll show you how, through the unique capabilities of ARB technology, you can obtain the optimal line layout to maximize productivity. Award-winning ARB technology has simplified line layouts and enabled critical improvements for end users in over 2500 installations worldwide.

JBT FoodTech

For the latest freezing and cooking technologies, JBT FoodTech continues to lead the way. The famous GYRoCOMPACT® spiral freezer, which includes the popular M series of freezers, is now available with several new upgrades for hygiene and sanitation: stainless steel fully seam welded enclosure, hygienic evaporator coil features and, lighter and stronger FRIGoBELT® M for higher freezing capacity . For high capacity, boxed product applications, Odenberg Variable Retention Time (VRT) freezers and chillers are now sold by JBT FoodTech in North America. From yogurt cooling to freezing boxed meat, the Odenberg VRT can integrate with existing cold storage warehouses to process large capacities of up to 50,000 lb/hr. The Double D Searing Oven with optional Bar Marker adds unique color and texture to products. For processors looking for the most economical way to extend oil life, the MicroMax™ (MX) Centrifugal Oil Filter is a proven winner. The new MX-II operates as a centrifuge to continuously filter out oil sediment down to 5-micron particles.

Committed to quality and performance-driven results, Intralox offers customers global industry expertise and 24-hour service. For country- and industry-specific phone numbers, visit www.intralox.com.

Contact: Intralox, L.L.C. 301 Plantation Road Harahan, LA 70123 Phone: 1.888.427.2358 Fax: (800)877-7543 [email protected] See us at PACK EXPO Las Vegas Booth #C2424

www.RFFmag.com

Contact: JBT FoodTech 1622 First St Sandusky, OH 44870 (419)626-0304 www.jbtfoodtech.com [email protected] See us at PACK EXPO Las Vegas Booth #6218

Refrigerated & Frozen Foods SEPTEMBER 2011 47

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW PREVIEWS SPECIAL ADVERTISING SECTION

Kliklok-Woodman

At KW we understand that selecting the right packaging machinery is a crucial decision for the success of any product, particularly in the food industry. For over 60 years, Kliklok-Woodman has been at the forefront of food packaging technology. We work with our customers to ensure they choose equipment that suits their individual needs and production requirements. Our extensive range of versatile and reliable equipment includes vertical form-fill-seal bagmakers, weighers and filling systems; topload, endload and wraparound cartoners; product handling and indexing machines; and unique specialty machines. Kliklok-Woodman is able to anticipate the changing needs of our customers because our expertise is focused on the core industries we have served for so many years: bakery, snack foods, frozen/prepared foods, cereal and related industries. This focus helps us keep you one step ahead of today’s evolving marketplace. For almost seven decades Kliklok-Woodman has grown from respected pioneer to expected innovator in packaging machinery. Why? Simple: we continuously invest considerable effort and resources to ensure that our packaging machinery remains the number one choice for food producers worldwide. The world’s most trusted brands trust KW! Performance is Guaranteed. Technology is Advanced. Support is Assured. Longevity is Proven…. ASK OUR CUSTOMERS and SEE THE INNOVATION!

Orics

ORICS Industries is one of the leaders and innovators in Modified Atmosphere Packaging and Tray Sealing Technology. Since the start of the current trend of extended shelf life for refrigerated foods, ORICS has been the premier supplier demonstrating the capability of meeting many customers’ varied specific requirements. Investing in a tray sealing packaging machine will improve the product shelf-life and appearance. Whatever your market may be: Home Meal Replacement, Fresh Fruits and Vegetables, Snacks, Appetizers, Soups and Dips, Side Dishes, Meat, Poultry, Seafood, Dairy Foods, Medical and Pharmaceutical – ORICS has the experience to provide you with solutions for your packaging needs. we produce complete packaging lines customized for your needs; From automatic tray de-nesting, filling systems, conveying, sealing and over-capping. ORICS answer to Sustainability in Packaging Equipment Most sealing machine in the market requires excess film and increased labor time as well as low productivity. The unique design of the S-30 and CMTS Eco-Cut proved to be a perfect fit for leading processors in the fresh produce segment. The S-30 AND CMTS’s Eco-Cut® film feeder technology offers added benefits. Film is cut in between each container, leaving no wasted film and saving the packer more than $35,000 a year. The approach also minimizes environmental impact by decreasing the amount of material discarded. ORICS customized the system to include registered film slice-cut mechanism to handle printed film. By reducing input cost for the ongoing purchase of the lid material (film), the CMTS practically pays itself off, turning once again eco-design into positive profit. The S-30 and CMTS Eco-Cut will increase your productivity by eliminating the manual packing process and help free up employees to handle more strategic tasks within your organization. ORICS Industries invites you to visit us at Booth # 403 For more details please contact us: 718.461.8613 www.orics.com We are proud to design, fabricate and manufacture food and pharmaceutical packaging machinery in the United States of America.

Contact: 5224 Snapfinger Woods Drive Decatur, GA 30035 USA Tel: 770-981-5200 [email protected] www.kliklokwoodman.com See us at PACK EXPO Las Vegas Booth #1400

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Refrigerated & Frozen Foods SEPTEMBER 2011

Contact: Orics Industries Inc. Phone: (718) 461-8613 Email: [email protected] Web: www.orics.com See us at PACK EXPO Las Vegas Booth #403

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW PREVIEWS SPECIAL ADVERTISING SECTION

Petro-Canada Lubricants

REFLO puts the freeze on maintenance costs At Petro-Canada, we appreciate that controlling and reducing costs is essential to your business, and we pride ourselves in offering a complete solution. Our full line of REFLO™ compressor fluids, with proper maintenance, helps reduce fluid consumption, minimizes downtime, protects equipment and saves you money. REFLO has helped companies worldwide significantly reduce their lubrication costs: up to 80% in some cases. Visit Petro-Canada at the 2011 Process Expo to learn more about our full line of REFLO products. Also featured at the show will be Petro-Canada’s full line of PURITY™ food-grade lubricants, designed for many applications in food processing plants. These specially formulated food-grade lubricants are effective under severe food processing operating conditions — from food acids and juices to by-products and temperature swings.

At Petro-Canada, we’re going beyond today’s standards 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. At Petro-Canada, we believe you have to go beyond accepted limitations to deliver the leading-edge products that customers demand. When it comes to delivering the ultimate in lubrication, Petro-Canada is a global leader. Contact: Petro-Canada Lubricants 2310 Lakeshore Rd. West Mississauga, Ontario L5J 1K2 Tel: 905 804 3636 Fax: 905 804 3619 URL: lubricants.petro-canada.ca Email: [email protected] See us at PACK EXPO Las Vegas IDFA Show

www.RFFmag.com

Raque Food Systems, LLC

Founded in 1975 with the goal of providing packaging equipment to the Food Industry, Raque Food Systems has grown into a world-class manufacturer of industrial food-plant machinery.

Raque manufactures: Turn-Key material handling production lines for preformed packages that come complete with: • • • •

Touchscreen-based controls. Centralized line management. Multi-tiered security. Statistical analysis.

Extremely accurate filling and depositing equipment for solid and fluid products. Fully automated Pie Systems in either double crust, high-rim, or cheesecake pie crusts. Entire pizza systems for border free or waterfall applications. State-of-the-art heat-seal machinery with speeds from 20 to 300 Units per Minute. Other equipment include: Dough Laminators, Rotary Plate Fillers, specialty items, and much, much more. Raque Food Systems has the ability to customize and design almost any machine to fit your needs. Today, more than a quarter century after its inception, Raque Food Systems, operates with the same management and with the same dedication to the sectors that gave us our start. With at least 30 industrial food-plant machinery patents in 6 different nations and independent sales offices in Louisville, Kentucky (U.S.A.) and in Hallow, Worcester (U.K.), Raque Food Systems, LLC is truly a world-class manufacturer. Although we ship machinery to companies all around world, we have not forgotten our roots. The majority of our sales still come from repeat customers, customers who have purchased machinery from us, customers who have experienced firsthand the post-sale service we provide, and customers who look to us as the industry standard. So give us a call and find out what Raque can do for you!

Contact: Raque Food Systems, LLC 11002 Decimal Dr. P.O. Box 99594 Louisville, KY 40269 (502) 267-9641 [email protected] www.raque.com See us at PACK EXPO Las Vegas Booth #1229

Refrigerated & Frozen Foods SEPTEMBER 2011 49

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW PREVIEWS SPECIAL ADVERTISING SECTION

Reiser

Triangle Package Machinery Reiser supplies a complete line of equipment to help food processors produce all types of prepared food and deli SALADPRODUCTS/URRANGEOFEQUIPMENT INCLUDES!-&%#MIXERS 6EMAGPORTIONERS 6EMAGCUPFILLERS AND6EMAGSLICE depositors for sandwich making.

AMFEC Mixers !-&%#-IXERSAREIDEALFORGENTLE blending and mixing of even the most DELICATEPRODUCTS!VARIETYOFAGITATOR options are available, including their exclusive Faster Mix agitators (both paddles and ribbons), which eliminate the “logging” effect often seen in other Mixers. Vemag Portioners 4HE6EMAG0ORTIONERISAFOODPUMPTHATPROVIDESTHEHIGHESTLEVELOF portioning accuracy, production efficiency and versatility, while consistently PRODUCINGAHIGH QUALITYPRODUCT4HE6EMAGFEATURESAPOWERFUL POSITIVE displacement double-screw pump that transports product extremely gently and WITHOUTDAMAGE!VARIETYOFINNOVATIVE ATTACHMENTSMAKETHE6EMAGAHIGHLY versatile machine. Vemag Cup Fillers 4HE6EMAG0ORTIONERWITHA$RIPLESS 6ALVEFILLINGHEADATTACHMENTCANBEUSED to fill all types of containers – cups, tubs, pails and trays – accurately and gently without mess or container contamination. This is an economical solution to easily fill containers with exact-weight portions. Vemag Slice Depositors 4HE6EMAG0ORTIONERWITHA3LICE$EPOSITORATTACHMENTISTHEPERFECT SOLUTIONFORPRODUCINGALLTYPESOFSANDWICHESQUICKLYANDEASILY)TDEPOSITS exact-weight portions of product mixtures such as tuna salad, chicken salad ORCONDIMENTSPREADSDIRECTLYONTOSANDWICHBREAD)TPORTIONSCLEANLYAND evenly, with no mess.

Contact: $EDHAM3TREET #ANTON -!  4ELEPHONE   &AX   [email protected] www.reiser.com See us at PACK EXPO Las Vegas Booth #5335

50

Refrigerated & Frozen Foods SEPTEMBER 2011

Family-owned and operated since 1923, Triangle Package Machinery supplies industry leading solutions that continually make our customers more competitive. With a diverse product line that includes vertical form/fill/seal baggers, combination weighers, and bag-in-box systems, Triangle is truly your single source for packaging automation. s&ASTER/URHIGHSPEEDBAGGERSCAN run a variety of bag styles in both poly and cello film with quick, tool-less changeover. s#LEANER$ESIGNEDTOWITHSTANDTHE harshest environments, our baggers are available in three levels of sanitation: painted steel, stainless steel, and 53$!!MODELS s3MARTER(IGHER/%% INTUITIVEMACHINES ANDTHEABILITYTOSEALBAGSWITH traditional heat sealing or Ultrasonic welding. Whether you are an existing partner or a potential customer, we are confident our expertise will help you find the proper solution to your PACKAGINGCHALLENGE3TOPBY"OOTH# ANDSEEHOWWECANAPPLYOUR technology and innovation to make you more competitive.

Contact: Triangle Package Machinery 7$IVERSEY!VE #HICAGO ), 0HONE   Email: [email protected] Web: www.trianglepackage.com See us at PACK EXPO Las Vegas Booth #1223

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N O V E M B E R 7-9, 2011 INTERCONTINENTAL BUCKHEAD • ATLANTA, GA

PREDICTIONS FOR PACKAGING Packaging Strategies’ NEW Packaging Outlook Summit will offer a window on innovation and showcase trends and predictions in containers and materials. • Discover emerging trends in containers and materials and how they will influence packaging • Hear bold forecasts and predictions from expert sources on the future direction of packaging • Learn more about the innovation process and how it can support expansion opportunities • Network with top CPG producers/brand owners in a relaxed environment • Find the latest packaging materials, solutions and services at the Tuesday evening exhibition reception Complete program will be available in July 2011

www.PackagingOutlook.com Produced By:

Media Partner:

Supported By:

Classified Network

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

CO-PACK MANUFACTURING SERVICES

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 • Tray Lines • Rheon® Technology

• Enrobing (Bake/Par-Fry) • Proofing/Baking • Multi-Component Fill • Drop-In Pouch Enclosure • In-House Pasta Blanching • Fully Integrated In-House

(up to 4 oz. shapes)

• Hand Rolled Line • Breading Line

Component Processing

Packaging Capabilities

• Vegetable Blending • RTE • USDA/FDA Certified • HCCAP Program • X-Ray Scanning • Metal Detection

• Aluminum Tray (3 to 10 lbs.) • Dual Ovenable/Microwavable Tray (10 to 44 oz.) • Boil-In-Bag • Gusseted Multi-Component

• Steamable Bag/Film • Tray In Carton • Eat Out Of The Box • Bulk Pack

Bag/Film

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

EQUIPMENT FOR SALE

Refrigerated Containers Practical

Now Renting

Inexpensive

Quick

We sell world wide. 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.

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

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

(856) 241-9970 www.terlotherm.com

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

www.kellyfreezer.com 52

Refrigerated & Frozen Foods SEPTEMBER 2011

www.RFFmag.com

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

Classified Network

EQUIPMENT FOR SALE

Cryo-Jet® Cooling Fan • Faster cooling of hot food products using ambient air. • Reduces build up of frost/ice in continuous freezers.

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

WANTED TO BUY

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Refrigerated & Frozen Foods SEPTEMBER 2011 53

ADINDEX Advertiser

Americold Logistics

ADVERTISING Page

2

E-mail/Website

www.americoldrealty.com

Ashworth Bros., Inc

25

www.ashworth.com

Buhler Sortex Inc.

26

www.buhlergroup.com

CAS Dataloggers

28

www.dataloggerinc.com

Coastline Equipment, Inc.

44

www.coastline-equipment.com

Delkor

29

www.delkorsystems.com

Demaco

30

www.defranciscimachine.com

Exopack

3

www.exopack.com

FPSA

8-9

www.myprocessexpo.com

The Fricks Company

24

www.thefrickscompany.com

Harpak-Ulma

15

www.harpak-ulma.com

Hinds-Bock Corporation

32

www.hinds-bock.com

Intralox

23

www.intralox.com

Jacobs

31

www.jacobs.com

JBT FoodTech

10, 37

www.jbtfoodtech.com

Kliklok Woodman

12

www.kliklokwoodman.com

M&M Refrigeration

7

www.mmrefrigeration.com

MCBI

41

www.ecoficientseries.com/rff

Miami Frozen Storage

21

www.miamifrozen.com

Nelson Jameson Inc.

28

www.nelsonjameson.com

OSI Group Raque Food Systems, Inc.

13, 33

www.osigroup.com

5

www.raque.com

16, 39

www.reiser.com

Stoops Freightliner

14

www.stoops.com

Triangle Package Machinery Co.

27

www.trianglepackage.com

Reiser

United States Cold Storage, Inc.

Back Cover

www.uscold.com

Washington Cold Storage

14

www.washingtoncoldstorage.com

Westby Cooperative Creamery

31

www.westbycreamery.com

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

Patrick Young Publisher & District Sales Manager 600 Willowbrook Lane, Suite 610 West Chester, PA 19382 [email protected] Tel: 610-436-4220, ext. 8520; Fax: 248-502-2123 Mid-Atlantic Territory: CT, Eastern PA, NJ, NYC and LI, VA, MD, DE, Washington DC

Paul Kelly District Sales Manager 155 N. Pfingsten Rd., Ste. 205 Deerfield, IL 60015 [email protected] Tel: 847-405-4048; Fax: 248-502-1017 Midwest and Northeast Territory: Northern IL, WI, MN, IA, KS, 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 [email protected] Tel: 440-564-5732; Fax: 248-502-2088 Midwest and Southeast Territory: OH, IN, WV, KY, TN, MI, NY, Western PA, FL, GA, NC, SC, AL, Southern IL, MS, LA, Ontario, Quebec

Wayne Wiggins, Jr. District Sales Manager 454 Funston Avenue San Francisco, CA 94118 [email protected] Tel: 415-387-7784; Fax: 415-387-7855 West Coast Territory: AZ, CA, OR, WA, AK, UT, ID, HI, British Columbia

Carolyn Dress Sales Representative 155 N. Pfingsten Rd., Ste. 205 Deerfield, IL 60015 [email protected] Tel: 847-405-4046 Fax: 248-502-9104

Suzanne Sarkesian Internet and Classified Sales Manager [email protected] (248)786-1692

READER & MARKETING SERVICES LETTERS Bob Garrison Refrigerated & Frozen Foods 517 N. Michigan St. Plymouth, IN 46563 [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)244-1726

LIST RENTAL Kevin Collopy at 800-223-2194, ext. 684 Michael Costantino at 800-223-2194, ext. 748

FREE Mobile App New for 2011, PROCESS EXPO attendees have access to a FREE show directory mobile app. Exhibitors, conference schedules, show Áoor maps and local area resources at attendees’ Àngertips!

Take a picture of the mobile tag below with your smartphone or go to www.myprocessexpo.com/ mobileapp and download the PROCESS EXPO show directory mobile app today! NOTE: First time mobile tag users will need to download the free mobile tag app. at http://gettag.mobi.

A Natural Solution... USCS Logistics and SmartWay Transport

Your Supply Chain can work toward protecting our environment. USCS Logistics has been approved as a SmartWay Transport Partner that offers full scale transportation management solutions while reducing air pollutant emissions to help create a sustainable environment for generations to come.

www.uscoldstorage.com USCS Logistics Tel 856.380.8025 | Headquarters Tel 856.354.8181 | National Sales Tel 510.471.1703