Food Engineering October 2011

SPECIAL REPORT: PROCESSORS BALANCE THE NEED FOR AUTOMATION VS. FLEXIBILITY October 2011

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THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT

State of Food Manufacturing

Processors Trim Spending

ALSO THIS MONTH `

LEGACY SYSTEMS: WEIGHING THE COSTS, BENEFITS, RISKS ` PROCESS EXPO PREVIEW ` TECH UPDATE: PUMPS

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O CTO B E R 2011

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FEATURES

Brick & mortar projects still struggling

COVER STORY

66

The State of Food Manufacturing Staff expansions and production efficiencies are bright spots in an industry feeling the effects of economic forces beyond its control.

Legacy Systems: Weighing the Costs, Benefits and Risks Most replacement systems will, or at least should, provide marginal benefits over your legacy system.

89

Flexible Manufacturing: The Automation Conundrum

Tech Update: Pumps The right pump used for the right application can make a significant difference in energy consumption.

600 500 400 300

Flexibility is an increasingly important attribute, but manufacturing professionals must strike a balance between the need for high-speed automation and production adaptability.

99

Total Projects* Expansions/Renovations New Plants

700 Number of projects

79

800

200 100 2001

2002

2003

2004

2005

2006

2007

2008

2009

2010 14-year average

*Based on projects valued at $1 million or more Source: Food Engineering’s Food Plant Construction Survey.

DEPARTMENTS 8

70

Editor’s Note

10

Calendar of Events

13

Manufacturing News PROCESS EXPO heads to Chicago bigger than 2010 show.

19

Food Packaging Front-of-package slugfest

25

89

Ode to the pallet

27

112

Join FE’s Group on LinkedIn Food Engineering Magazine

Field Reports Snack food maker cleans up its wastewater.

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

Technology Sourcebook Focus on Kettles, Tanks, Process Vessels and Marking & Coding Equipment

Connect with FE on Facebook www.facebook.com/FoodEngineering

Food Safety

115

PROCESS EXPO Preview

135

Classified Advertising

143

Engineering R&D GE salmon swim upstream.

www.foodengineeringmag.com | Food Engineering | October 2011

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EDITORIAL Joyce Fassl Editor in Chief [email protected], 610-436-4220 ext. 8519 Kevin T. Higgins Senior Editor [email protected], 847-405-4045 Wayne Labs Senior Technical Editor [email protected], 215-345-4548 Morgan Smith New Products Editor [email protected] Richard Stier, Jaan Koel, Allen Merritt, Mark Huffman, Olin Thompson Contributing Editors ART & PRODUCTION Karla Fierimonte Art Director [email protected] Suzanne Fairman Advertising Production Manager [email protected], 253-946-6854 MARKETING Marge Whalen Food Automation & Manufacturing Conference Manager [email protected], 847-405-4071 Amy Kozyra Marketing and Event Coordinator [email protected], 847-405-4022 Chris Frost ProcessTechnologyXchange [email protected], 952-224-4390 Jill L. DeVries Corporate Reprint Manager [email protected], 248-244-1726 LIST RENTAL Kevin Collopy Postal Contact 800-223-2194 x684, [email protected] Michael Costantino Email Contact 800-223-2194 x748, [email protected] AUDIENCE DEVELOPMENT Amy Schuler Group Audience Development Manager Megan Neel Corporate Fulfillment Manager Carolyn M. Alexander Audience Audit Coordinator

YOUR EXPERTS IN UPTIME When there’s no time for downtime and equipment failures are not an option, you need a proven solution you can trust. At Inpro/Seal, we combine extensive application experience and field–testing with a robust development process to deliver the best performing products–guaranteed. Your custom engineered Inpro/Seal Air Mizer® is a permanent non-contacting shaft seal designed to prevent product loss, harmful emissions and contamination. We deliver technology that improves the reliability of rotating equipment… standard with every Inpro/Seal solution.

FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT: Tel. 847-763-9534 or Fax 847-763-9538 or e-mail [email protected]

FOOD ENGINEERING Volume 83, Issue 10 (ISSN 0193-323X) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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See Food Master, p. 64

EDITOR’S NOTE

Calling all innovators

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

n the past few months, I have written about the many changes that continue to occur in our industry. Funding for capital expenditures returned to normal last year, but as 2011 winds down, members of the food industry are once again tightening their budgets. According to our cover story on the State of Food Manufacturing, the budget news is not dismal, but it’s far from some of the glory years of the past decade. Despite recent economic ups and downs and budget instability, fantastic food plants continue to be built year after year. Before 2011 winds down, you will be reading about the Sustainable Plant of the Year and the annual Fabulous Food Plant on the pages of Food Engineering. Now is the time to begin preparing your entry for FE’s top honor, the 30th Annual Plant of the Year award. Entries are due December 1, 2011. Any food or beverage plant or project that became fully operational in 2011 is eligible to enter. Entries will be judged according to the following criteria: • Contribution to the company’s actual or projected long-term business plan; • Level of innovation in processing and packaging line design;

• Building and site design innovation; • Productive integration of workforce into the overall plan; • On-time/on budget performance; • Food safety innovation; • Use of new automation and software technologies; • Flexible manufacturing; • Supply chain management and enterprise resource planning; • Worker safety innovation; and • Environmental impact. The award is not limited to greenfield projects. Major expansions, renovations or brownfield plant projects are eligible to enter the competition. A detailed narrative of 10 pages describing the plant, based on the criteria above, is required. In addition, the facility must be available for a visit by Food Engineering staff in January or February 2012. If you are interested in joining the ranks of past Food Plant of the Year winners such as Shearer’s Foods, Keystone Foods and Barilla America, please email me at [email protected] for further information or visit www.food engineeringmag.com to download an official entry form and view instructions and requirements for entering the competition. I look forward to hearing about your latest innovations. ❖

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

8

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

October 2011 | Food Engineering | www.foodengineeringmag.com

Alex Peele Director of Project Engineering Interstate Brands Corp.

Dan Sileo Vice President, Manufacturing Sunny Delight Beverages

Diane Wolf Former Global Vice President, Safety and Environmental Sustainability Kraft Foods

David Haase Vice President of Operations WILD Flavors

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

JANUARY 2012 15-18: 98th Annual NW Food Manufacturing & Packaging Expo and Conference; Oregon Convention Center, Portland, OR; Northwest Food Processors Association; www.nwfpa.org 24-26: International Poultry Expo; Georgia World Congress Center, Atlanta, GA; US Poultry & Egg Institute; www.poultryegginstitute.org

FEBRUARY 2012 6-9: ARC World Industry Forum; Renaissance Orlando at SeaWorld Marriott, Orlando, FL; ARC Advisory Group; www.arcweb.com 28-March 3: IPACK-IMA; Fiera Milano, Italy; Ipack-Ima spa; www.ipack-ima.com

MARCH 2012 17-19 SNAXPO; Phoenix Convention Center, Phoenix, AZ; Snack Food Association; www.snaxpo.com 27-30: Anuga FoodTec; Koelnmesse GmbH; www.koelnmesse.de

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MANUFACTURING

`NEWS PLANT OPENINGS & EXPANSIONS The Dairy Farmers of America is making a $13.4 million capital investment in its plant in Plymouth, WI.

PROCESS EXPO 2011 heads to Chicago, doubles size from 2010

Green Gourmet of Ohio is locating a new plant in the former Fresh Vegetable Technology building in Baltimore, OH. The $8.4 million plant is expected to create 123 full-time jobs. The company produces microwaveable frozen potato products. Seymour Dairy Products celebrated the opening of an 11,000-sq.-ft. expansion at its cheese processing plant in Seymour, WI. The $2.5 million project will increase the plant’s capacity for making specialty cheeses, of which its main product is blue cheese. Union County Livestock will expand its 31,000-sq.-ft. Uniontown, KY plant by adding a new production line to its existing facility. The $860,000 project will create 25 new full-time jobs. The company plans to add a smokehouse and other equipment for a new product line of barbequed items. Augusta, GA-based FPL Food, LLC will expand its beef processing operation in Richmond County by opening a new processing facility, creating up to 100 new jobs. The company will invest $3 million in this expansion. FPL Food, a privately held beef processor, serves foodservice, retail, military and export operations, with capabilities ranging from traditional beef cuts to value-added retail products.

T

he Food Processing Suppliers Association (FPSA) reports this year’s PROCESS EXPO has doubled the exhibit space of the 2010 show. PROCESS EXPO 2011 has surpassed the milestone of 200,000 sq. ft. set for this year, and has signed on more than 400 exhibitors. FPSA is expecting over 10,000 attendees from more than 75 countries. The show, which also features a comprehensive collection of conference sessions, runs from November 1 through November 4, 2011 at McCormick Place South in Chicago, IL. Those who miss this year’s EXPO will have to wait two years for the next show. FPSA management, in concert with association members, decided to follow the European model for scheduling trade shows—every two or three years. Therefore, the next PROCESS EXPO will be held in 2013. PROCESS EXPO also features nearly 30 hours of educational programming. With the new FDA Food Safety Modernization Act (FSMA) and sustainability being hot topics, organizers are expecting

` More than 400 exhibitors will participate in PROCESS EXPO 2011 this November in Chicago. Source: FPSA.

a heavy turnout for the conference sessions. The sessions are free with the expo registration, but attendees need to sign up well in advance for individual sessions if they want to be assured of being admitted. “The seminar program has been listed online for just weeks,” says David Seckman, president of FPSA “and the early registration has been remarkable.” Due to attendee demand, Seckman says FPSA has “expanded the seating of all the meeting rooms and the Siemens Educational Theater on the show floor to serve an audience of almost 100 people per seminar.” The 2011 educational program, “Manufacturing Solutions: Practical Responses to Food Industry Challenges,” takes place at the start of each day of the show. It focuses on key issues of concern in the food and beverage industry and practical solutions processors can use in their operations.

www.foodengineeringmag.com | Food Engineering | October 2011

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MANUFACTURING

`NEWS “Seminario de Innovaciones” is dedicated entirely to attendees from Latin America and runs on October 31. These sessions are presented in Spanish and sponsored by PROCESS EXPO’s international partners: CANAINCA, CANILEC, COMECARNE and Chilealimentos.

Siemens Exhibitor Spotlight Theater will host a series of short technical workshops each day on the show floor, covering a wide variety of topics of interest to food processors. Issues surrounding food safety are paramount in the educational offerings. The topic will be approached from a variety of

` FPSA is expecting over 10,000 visitors to PROCESS EXPO 2011. Source: FPSA.

perspectives and discussed by representatives of organizations including NSF, International Poultry and Egg Association, and the National Association of Meat Processors. Industry consultants, trade press members and experts representing some of the leading exhibitors round out the faculty. In addition to food safety, sessions on sustainability, newly emerging technologies, energy and water management, doing more with less and finding and keeping good employees are generating interest from registrants. The FPSA Councils Pavilion (Booth 5412) gives attendees a chance to meet with representatives from different industry councils within FPSA. Members will be on hand to discuss how processors and suppliers can collaborate on key issues. The Pavilion features a different council each day: Tuesday, November 1, Meat Industry Suppliers Alliance (MISA); Wednesday, November 2, Bakery Council; Thursday, November 3, Prepared Foods Council; and Friday, November 4, Dairy Council. Exhibit hours are 9:00 a.m.-5:00 p.m. from Tuesday (November 1) through Thursday (November 3) and 9:00 a.m.2:00 p.m. on Friday (November 4). Registration starts each day an hour before the exhibits open and continues until the show closing time. Seminario de Innovaciones will be held on Monday (October 31) from 9:00 a.m.-3:00 p.m. with registration open from 8:00 a.m.3:00 p.m. For more details on the technical sessions, see page 115. 14

October 2011 | Food Engineering | www.foodengineeringmag.com

REGULATORY WATCH Bill addresses obesity Rep. Marcia L. Fudge (D-OH), who introduced a bill called the Fit for LIFE Act, has updated the proposed legislation, adding language that would provide at-risk children with access to nutritious foods on weekends and during school holidays. The measure is aimed at combating childhood obesity. “The food and beverage industry supports this comprehensive, common sense approach to help young Americans—especially those in underserved communities—build healthy diets and lead active lifestyles,” says Grocery Manufacturers Association President and CEO Pamela G. Bailey.

Federation (NMPF), which represents dairy farmers, says eliminating the Dairy Product Price Support Program would make the US dairy industry more competitive globally. “Once this program is eliminated, markets, during periods of surplus,

will clear more quickly,” NMPF Board Member Les Hardesty says. The International Dairy Foods Association says the policy would have the opposite effect. It says US dairy exports would have dropped significantly had it been in place in 2009, when dairy prices plunged.

Should menu labeling apply to supermarkets? The Food Marketing Institute (FMI) says 36 members of both the US Senate and House of Representatives have sent letters to the FDA urging the agency not to expand chain restaurant menu labeling regulations to grocery stores. The letters strongly suggest FDA adopt the agency’s own alternative to limit the scope of the restaurant menu labeling rule to restaurants with menus or establishments that primarily sell restaurant foods. “We believe these letters clarify that members of Congress did not intend for the recently passed chain restaurant menu labeling law to be applied to supermarkets,” says FMI CEO Leslie G. Sarasin. The trade group says including grocery stores in the new regulation would be unworkable, as well as redundant, since 95 percent or more of their food products are labeled with calorie information as well as a nutrition facts panel.

Dairy industry at odds Dairy producers and processors are at odds over proposed dairy export policy reforms. The National Milk Producers www.foodengineeringmag.com | Food Engineering | October 2011

15

MANUFACTURING

`NEWS INDUSTRY & PEOPLE New Zealand-based Fonterra and UKbased First Milk announced a strategic joint venture to produce premium whey proteins for Fonterra’s growing food ingredients business.

Covance entered into a definitive agreement to acquire TRAC Microbiology, Inc., a Madison, WI-based food microbiology and chemistry laboratory. TRAC provides testing, research, auditing and consulting services.

Rice Lake Weighing Systems purchased a 29,700-sq.-ft. manufacturing facility in Fernley, NV where the company plans to expand truck-scale manufacturing and improve service to its Western heavy-capacity customers. Sara Lee Corp. named Michiel Herkemij as chief of its international beverage business; he will lead Sara Lee’s CoffeeCo segment once it is spun off. Cleveland-based Athens Foods appointed Scott Sumser as president. Dannon unveiled its $9 million Discovery and Innovation Center at the French company’s American headquarters in Greenburgh, NY. Blue Diamond, the US almond grower and manufacturer, announced that its Sacramento manufacturing facility was named “Plant of the Year of the Pinnacle Club” by the American Council for Food Safety & Quality, also known as the DFA of California. Plaza Belmont Fund II LLC sold the tortilla-production assets of Casa de Oro Foods LLC to Gruma Corporation for $20 million. The Coca-Cola Company and its Chinese bottling partners announced a new investment of $4 billion over the next three years commencing in 2012. MegaMex Foods, a joint venture of Hormel Foods and Herdez Del Fuetre, acquired Fresherized Foods, maker of Wholly Guacamole and other products. Schenck AccuRate announced the grand opening of its renovated test center located in Whitewater, WI. The newly remodeled facility is equipped with all the necessary features for testing customers’ dry bulk solid materials in volumetric, gravimetric, vibratory and sanitary feeding configurations.

16

October 2011 | Food Engineering | www.foodengineeringmag.com

Crown Holdings, Inc., a supplier of metal packaging products worldwide, will continue to expand its footprint in China by building two new beverage can plants and adding a second line to an existing facility.

The Grocery Manufacturers Association and its Associate Member Council awarded General Mills and Batter Blaster with the 2011 CPG Award for Innovation and Cre-

ativity. The award is given annually to companies that have demonstrated creativity, innovation, and have made a significant impact on the industry knowledge base.

TÜV SÜD America Inc., a global testing, inspection and certification services firm, named Ian Nicol as president and CEO for Americas operations, including TÜV SÜD Canada, TÜV SÜD América de México and TÜV SÜD America do Brasil. Key Technology appointed Richard van Densen as product marketing manager at Key Technology BV, the company’s European operation. Dannon appointed Eric O’Toole as senior vice president of the company’s foodservice and restaurant business, Luciano LopezMay as senior vice president of sales and Sergio Fuster as its new senior vice president of marketing.

NE

W

Pearson Candy was acquired by private equity firm Brynwood Partners. C. F. Sauer has sold its Dean Foods margarine operations, including a plant in Sandston, VA, to St. Louis-based Bunge North America. Provisur Technologies, Inc. acquired TS Techniek B.V., a technology-driven, food processing equipment manufacturer based in Pijnacker, the Netherlands. This is the second European acquisition for Provisur this year. Australia’s Foreign Investment Review Board has cleared the way to a joint venture between Cargill Beef Australia and Teys Bros. The new company will be a 50-50 joint venture and trade under the name of Teys Australia – A Cargill Joint Venture. Krones AG, Neutraubling, Germany, signed a cooperation agreement with the folding-carton producer and multipack specialist A&R Carton Bremen GmbH, located in Bremen, Germany.

www.foodengineeringmag.com | Food Engineering | October 2011

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

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

SSO-FG Series - For Canning Equipment • Designed specifically for use in Angelus Seaming Machinery. • High Performance, 100% Synthetic Fluid Lubricants. • Unsurpassed anti-wear, anti-rust and corrosion protection.

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

Front-of-package slugfest

`

Months before its launch, the Nutrition Keys labeling program drew the ire of public health experts and some critics within the food industry.

T

outing the Nutrition Keys front-of-pack nutrition labeling program as “the most significant modernization of food labels since the Nutrition Labeling and Education Act of 1990,” executives at the Grocery Manufacturers Association (GMA) and retailer trade group Food Marketing Institute said they were taking aim at childhood obesity and shoppers’ demands for more nutrition information when introducing the program in January. But months before the system was scheduled to appear on grocery shelves this fall, Nutrition Keys was stirring criticism from multiple fronts. Nutrition Keys follows a similar trade association effort in 2009 called Smart Choices, a front-of-pack checkmark meant to steer shoppers to good-foryou food products. Soon after Connecticut’s thenAttorney General Richard Blumenthal requested information about the nutrition claims for products displaying the Smart Choices label such as Froot Loops and Cocoa Krispies from their manufacturers, the program was abandoned. Smart Choices did succeed in raising awareness of the many systems that deliver at-a-glance information on nutritional content. FDA Commissioner Margaret Hamburg and the Centers for Disease Control and Prevention convened an independent expert committee of the Institute of Medicine (IOM) to review the issue and make labeling recommendations. The first phase was completed in October 2010, with final recommendations due this fall. The IOM panel reviewed a sampling of 20 label programs created by manufacturers, retailers and

` Icons for key nutrients provide an at-a-glance food guide under Nutrition Keys, a trade group initiative that is drawing criticism from public health experts and some food companies. Source: Grocery Manufacturers Association.

other groups. Some were classified as nutrient-specific, similar to Kellogg’s Nutrition at a Glance and General Mills’ Nutrition Highlights and Goodness Corner. Calories per serving and other key nutrients are flagged in those programs. A similar approach is taken with Nutrition Keys. The IOM committee’s Phase 1 report suggests including information on trans fats, saturated fats and sodium in front-of-pack callouts but excludes sugar per serving, citing insufficient evidence linking sugar to health issues such as obesity, hypertension and stroke. The GMA program excludes trans fats but includes sugar. It also gives manufacturers the option to include two additional callouts for other nutrients. Criticism of Nutrition Keys was leveled in June in the New England Journal of Medicine. In a column headlined “Front-of-package nutrition labeling—an abuse of trust by the food industry?” the authors, Drs. Jeffrey Koplan and Kelly Brownell, criticized Nutrition Keys as confusing and lacking “a science-based, easily understood way to show consumers whether foods have a high, medium or low amount of a particular nutrient.” The doctors also questioned the program’s timing, which coincides with the release of the IOM committee’s final recommendations. Support for their conclusions has come from within the industry. In a statement released in July, Irwin D. Simon, CEO of Hain Celestial Group Inc., said Nutrition Keys “may disguise the true character of a product in order to induce purchase …. This seems similar to the Smart Choices program introduced last year by an overlapping group of companies.” Simon urged industry to wait for the IOM report “or risk being perceived as untrustworthy and inviting further government intervention.” GMA did not respond to telephone and e-mail requests for comment. Front-label nutritional information has expanded across many food categories in recent years, including fresh meat and poultry (see story on page 22). Despite the expansion, a third of the 1,200 shoppers who participated in a survey cosponsored by Sealed Air Corp. indicated they want more health and nutrition information when purchasing fresh meat and poultry. ❖

www.foodengineeringmag.com | Food Engineering | October 2011

19

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

Bag cracks Canadian cereal code ` A matte finish on a polybag lends an upscale look to Sally’s cereal, a new brand from MaltO-Meal and the company’s first product in the Canadian market. Source: Malt-O-Meal Co.

A

green package and an everyday low price helped Minneapolisbased Malt-O-Meal Co. unlock the keys to the Walmart kingdom north of the border with its new Sally ’s cereal brand, which debuted in Canada in July and is enjoying “overwhelming acceptance,” according to Linda Fisher, corporate communications manager. A major supplier of private-label cereals, Malt-O-Meal has aggressively promoted polybagged cereal to retailers in recent years as an alternative to conventional bag-in-box packaging. US firms produce 2.3 billion cereal boxes a year, says Fisher, and the polybag is positioned as a sustainable alternative to cardboard waste. The manufacturer tweaked the bag’s look, adding a matte finish and printing copy sideways on the resealable Sally’s bag. English and French copy convey the messages, “Go

boxless, go green” and “Every bite supports renewable wind energy,” a reference to the energy credits Malt-O-Meal purchases to offset electricity used in the cereals’ manufacture. “It was an opportunity to take our environmentally friendly package claim north of the border,” says Fisher, adding, “We knew that less packaging waste message would resonate in Canada.” It also was consistent with Walmart’s packaging material reduction programs, though the greater appeal is the $3 suggested retail price for up to 29 oz. of the cereal. Absent a trade promotion, comparable national brands retail for $6-$7 in Canada. ❖

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October 2011 | Food Engineering | www.foodengineeringmag.com

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S U C C E S S

S T O R I E S

HOW A VEMAG DEPOSITOR

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

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

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

Leading the food industry in processing and packaging solutions.

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

Retailers gear up for labeling mandate hree-fifths of meat and poultry prod- ` Raw meat and poultry increasingly ucts in grocers’ refrigerated lockers are being packaged with nutrition carry some form of nutrition infor- information. Source: Sealed Air Corp. mation, according to a comprehenUnder the USDA sive audit of meat-case packaging, almost double the ratio of rule, ground beef eight years earlier but leaving plenty of room for improvement before a USDA rule for nutrition labeling of raw meat and poul- labels that claim to be 85 percent lean try products kicks in January 1. Nutrition labeling and cooking information, either on the also must disclose package or at the point of sale, reflect changes by suppliers of the fat content. case-ready branded products and the growing sophistication of Veal and lamb are retailers’ scale systems, notes Jerry Kelly, national retail account the least likely meats to include nutrition information, though manager at Sealed Air Corp.’s Duncan, SC-based Cryovac they are expanding exponentially, with veal tripling and lamb division. A comprehensive survey cosponsored by Cryovac doubling their frequency in three years. Case-ready packaging indicates supplier-branded products in meat cases are dwin- is a factor, particularly with the leaner cuts. Raw turkey is the most likely product to currently carry dling, while store-branded goods have tripled since 2004 and now represent 36 percent of SKUs, virtually even with supplier nutrition information, in part because turkey producers “have a brands. But newer scales used by retailers go well beyond price great story to tell,” Kelly says. ❖ and weight, allowing them to include safe-handling and nutri- For more information: Jerry Kelly, Sealed Air Corp., 864-879-3861 tion information with many cuts.

T

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October 2011 | Food Engineering | www.foodengineeringmag.com

PERFORMANCE THROUGH ENGINEERING BETE HydroWhirl™ Orbitor

MaxiPass™ (MP) Nozzles from BETE

The XA Nozzle System from BETE

A New “Revolution” In Tank Cleaning BETE’s new HydroWhirl™ Orbitor is a versatile Clean-In-Place (CIP) rotating tank cleaning machine that combines high-impact cleaning efficiency with extended operating life, reduced life cycle costs and simple on-site service. The Orbitor can be completely stripped and rebuilt for maintenance ON-SITE in less than 15 minutes.

The ultimate in clog-resistance with the largest free passage available in a full cone nozzle Two unique s-shaped internal vanes allow free passage of particles equal to the orifice size, making the MP perfect for handling dirty, lumpy liquids. Pattern uniformity is exceptional, providing an even distribution throughout. Reliable spray under difficult conditions. Low flow model available.

Produces a no-drip or high-speed spray shut-off BETE’s low flow, air atomizing XA series nozzles provide very low flow rates. They are available in eight different spray patterns and numerous flow rates. The XA nozzles can be supplied with a number of hardware options to allow cleanout, shutoff of both. Hardware options are available in manual and pneumatic versions.

BETE is your strategic partner for engineered spraying solutions. Tank cleaning Mixing Coating Washing Drying Packaging

BETE HydroWhirl™ S A slotted rotating spray nozzle for quick, efficient tank cleaning The HydroWhirlTM S tank washing nozzle, with a 360° coverage, directs the cleaning water through a rotating head at the tip of the spray assembly. This spray pattern uses impact and repetition to quickly wash the tank which breaks up and removes contaminants. The low-maintenance, dual-bearing design, uses less water and lower pressure than static tank washers.

Twist & Dry™ Nozzles from BETE The Twist & Dry™ spray dry nozzle features the innovative thick swirl unit The robust design lasts longer, reducing dryer operating costs. The patented locking mechanism allows for quick and easy change-out and maintenance. BETE has expanded the range of the Twist & Dry™ series with the new TD-K, capable of operating at up to 10,000 psi.

BETE’s HydroWhirl tank cleaning nozzle

IN-HOUSE CAPABILITIES • 3D design, modeling, and measurement tools to create customized nozzle solutions • State-of-the-art spray laboratory to verify performance and supply detailed test results • Investment casting foundry for complete quality control and fast delivery • Specialized fabrication and welding expertise for multi-component assemblies PERFORMANCE THROUGH ENGINEERING Let our experience provide you with a recipe for success. www.bete.com

BETE Fog Nozzle,Inc.

BETE Fog Nozzle,Inc. BETE Fog Nozzle, Inc. 50 Greenfield St. Greenfield, MA 01301 T (413) 772-0846 F (413) 772-6729 www.bete.com

Rapid Microbial Testing Introducing the BD FACSMicroCount

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Reliable microbial testing. Faster. With the BD FACSMicroCount™ system, you get results with excellent correlation to traditional methods, but in a fraction of the time. Designed for quality microbial enumeration of pharmaceutical and personal care products, the system supports a wide range of applications for product testing, water analysis, and microbial fermentation. Using the BD FACSMicroCount system, you can perform qualitative (pass/fail) and quantitative (counts/mL) tests on a broad spectrum of microorganisms including bacteria, yeast, mold, and Mycoplasma. Automation makes it easy.

To optimize the BD FACSMicroCount system, BD sales and application specialists will work with you to test your products, train your team, and ensure a good fit to your unique manufacturing processes. Find out how the BD FACSMicroCount system can help you achieve the continuous manufacturing process improvements you’ve been looking for at bdbiosciences.com/microcount. Uncompromising microbial testing.

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FOOD SAFETY

Ode to the pallet

`

Keep an eye on one of the least considered plant tools. It could make a huge difference in your food safety plan.

ne of the least respected but most important tools for smooth food plant operation is the pallet. It brings in ingredients, raw materials and packaging materials; it moves things around the plant and finished goods out. Yet, in the hundreds of food plants I’ve visited, only a handful had a documented pallet management program. Pallet management should consist of the following elements: specifications, storage, inspection, use within and outside the plant , maintenance, shipping requirements Richard F. Stier, and cleaning. Contributing Editor If you store pallets outside, ensure they’re covered with an overhang and placed on rails or blocks a minimum of six inches above the ground since storing them on the ground allows those on the bottom to get wet and allow insects easy access. In addition, pallets should never be stored against walls either indoors or outside. Plus, don’t store pallets, which can harbor pests, close to access points. In production environments, pallets should be individually inspected before being brought into the warehouse or production area, especially when they’re stored outside. Many users equip the inspection area with compressed air hoses that allow the operator to remove pests and dirt. In addition, the inspection step must ensure pallets are in good condition. Any pallets that are splintered or have broken boards or loose nails should be set aside for repair or recycling. A pallet management program should define how pallets are cleaned and/or repaired. If plastic pallets are used, they should be washed according to the master cleaning schedule or more frequently if they’re badly soiled. Programs must also specify what products can be previously stored on pallets. For example, food and beverage processors should not accept pallets previ-

O

ously used to ship waste or chemicals, nor should they accept pallets that may be have been soiled with animal byproducts or waste. Independent laboratory studies have demonstrated pathogens and other indicator organisms can be isolated by soaking pallets in sterile water or soaking wood shavings from those pallets in the same medium. The work has demonstrated that past uses of the pallets clearly relate to the micro flora recovered. For example, Salmonella were routinely isolated from pallets used for poultry. The same requirements you demand of shipping containers should apply to pallets: clean, no infestation, no off-odors and used for foods only. There is a trend for processors to utilize both wooden and plastic pallets. The rule of thumb is that anything moving into the production area is moved on a plastic pallet. A plastic pallet can be cleaned and sanitized, and it eliminates the potential contamination from wood and metal (nails or staples) in a production area. In addition, some audit schemes will downgrade a facility for having wood in a processing area. To be effective, a pallet management program must be fully documented and managed. Work instructions or procedures should clearly define who is responsible for what, and outline procedures and expectations. All workers involved with the program must be properly trained and documented. To test your program’s effectiveness, conduct and document a risk assessment. Look for small gaps that could create problems in the future. Although pallets often don’t often get much respect, they have been implicated in infestations and cross-contamination with physical, chemical and biological hazards. Make sure that this simple yet essential tool does not pose a risk. ❖

www.foodengineeringmag.com | Food Engineering | October 2011

25

A frozen pizza producer needed to improve precision when applying oil to dough prior to baking to obtain a consistent calorie count and minimize waste. An AutoJet® Spray System with PulsaJet® automatic spray nozzles solved the problem. Operators select the oil application rate on the control panel based on the recipe and choose which nozzles are activated to cover the width of the dough being processed. During operation, when line speeds change, the spray controller ensures the proper volume of oil is uniformly applied to the dough.

The results: UÊÊ->ۈ˜}Ãʜ˜ÊœˆÊLÞÊiˆ“ˆ˜>̈˜}ÊÜ>ÃÌi\Ê 1-ÊfÎn]äääÊ>˜˜Õ>ÞÊ UÊÊ->ۈ˜}Ãʜ˜ÊVœ˜ÛiޜÀÊLiÌÊÀi«>Vi“i˜Ì V>ÕÃi`ÊLÞÊiÝViÃÃʜˆ\Ê1-Êf£Î]äääÊ>˜˜Õ>Þ UÊÊ >œÀˆiÊVœÕ˜ÌÊ«iÀÊ«ˆââ>ʈÃÊi>ȏÞÊÛ>ˆ`>Ìi`Ê `ÕiÊ̜ʫÀiVˆÃi]ÊVœ˜ÃˆÃÌi˜ÌʜˆÊ>««ˆV>̈œ˜ i>À˜Ê“œÀiÊ>LœÕÌÊ̅ˆÃÊ܏Ṏœ˜Ê >˜`ʅœÜÊÜiÊV>˜Ê}i˜iÀ>ÌiÊÀiÃՏÌÃÊ vœÀÊޜÕÊ>ÌÊëÀ>Þ°Vœ“ÉÀiÃՏÌð

1 +1 9Ê+1
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9

TECHNOLOGY S O U R C E B O O K Focus on Kettles, Tanks, Process Vessels and Marking & Coding Equipment

INVENTORY MANAGEMENT SOFTWARE FastPic5 inventory management software has a barcode scanning feature that improves the accuracy of put-and-pick transactions in food processing and distribution applications. With it, an operator uses a barcode scanner to scan an item as it is picked from a storage location. The software verifies the barcode and matches it to the part requested. The picker scans the part and then scans the location as the part is placed into inventory, verifying it is being placed in the correct storage location. The software can be configured to scan barcodes by transaction, type or material keyed to storage locations. Designed to manage manual and automated storage and retrieval systems, the software can also be configured to control single workstations and multiple work zones. FastPic Systems; 207-854-8663; www.fastpicsystems.com

HYDRONIC BOILER The Fulton 6,000,000 BTU/hr. input Vantage condensing hydronic boiler features thermal efficiencies up to 99% percent when firing on natural gas. The boiler tolerates varying system conditions, and features a condensing heat exchanger of Duplex alloy steel for corrosion resistance and low thermal expansion rates. High product mass and a large pressure vessel water volume design remove minimum water temperature requirements and reduce sensitivity to varying flow conditions, eliminating the need for boiler temperature control valves. The Fulton Companies; www.fulton.com

TANKS AND PRESSURE VESSELS Suitable for the food, dairy and beverage industries, Allegheny Bradford custom tanks and pressure vessels are individually designed and fabricated according to each processor’s specifications. Sizes range from 15 to 90,000 liters with a diameter of 14 feet. Materials include stainless steel and other nickel-based alloys. Certified ASME-coded vessels are available. Allegheny Bradford Corporation; 800-542-0650; www.alleghenybradford.com

www.foodengineeringmag.com | Food Engineering | October 2011

27

TECHNOLOGY Ingredients for a healthier business.

S O U R C E B O O K

If you run a food processing plant, using the wrong lubricant can mean more than just lost efficiency. It can directly lead to interrupted production due to food contamination. And that’s the last thing you want — because just one product recall can devastate your brand. And yet, while government agencies may require that lubricants be NSF H1 registered

where

incidental

contact

may occur, many lubricants used in the food industry today are not — putting production at risk. That’s why Mobil SHC Cibus Series food machine lubricants are NSF H1 registered. They’re specially formulated to help maximize productivity by combining food safety with high-performance lubrication. And engineered to perform longer than mineral oils, with the potential to provide

PROCESSOR KETTLE

extended run time and fewer oil drains —

A sanitary, high-performance cooker kettle, the Walker PZ-CB-K processor kettle performs high-speed mixing, blending, heating and cooling of a range of products including viscous materials. It features a cone bottom pitched to a center outlet and an agitator system of dual counteracting design. A scraper-type agitator has removable molded nylon blades that continuously wipe the bottom and sidewalls to blend product, increase heat transfer efficiency and aid in unloading. A counteracting agitator typically has an offset turbine-style blade to promote vertical movement to the mixing action. A stainless steel heat transfer jacket allows operating pressures up to 100psig at 320°F as standard; higher operating pressures and ASME and CRN code stamping are available. The processor kettle meets national and United States Public Heath Service requirements and the 3A Sanitary Standards for batch processors. Walker Engineered Products; 608-562-7557

helping increase machine availability at a time when minimizing downtime has never been more crucial. Synthetic lubricant performance with food safety built in? Now that’s a fresh idea. For more on Mobil SHC Cibus Series go to mobilindustrial.com.

THERMAL TRANSFER PRINTER

© 2011 Exxon Mobil Corporation Mobil, Mobil SHC, Cibus, and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.

1006_ENOD_Cibus_1_3_Ad.indd 1

Featuring a large print area, the Norwood 53XL thermal transfer printer allows users to print serialized, variable, batch and/or fixed text and graphics to packages and labels. Capable of printing GS1 barcodes for track-and-trace and electronic pedigree serialization, the printer

can achieve a print area up to 2 x 3.1 in. in size, and is available in intermittent motion for easy integration with a range of host equipment including vertical and horizontal form/fill/seal systems, primary labelers, thermoformers and overwrapping equipment. The printer can mark a variety of substrates with fixed and variable text. Text and graphics, including expiration dates, product identification information, lot-batch numbers, company logos and an array of linear and composite barcodes, can be printed both horizontally and vertically. It offers 300 dpi (12 dots per mm) resolution, printerresident barcodes, cassette ribbon loading, a thermal print head and a spent ribbon quick release. Norwood Marking Systems; 800626-3464; www.itwnorwood.com

9/13/11 3:53 PM October 2011 | Food Engineering | www.foodengineeringmag.com

Soaring productivity. How sweet it is.

Food processing plant managers must always balance a hunger for productivity with a need for product safety. That’s why we created the Mobil SHC Cibus series, a range of NSF H1 registered synthetic food machine lubricants that are designed to not only protect your food processing machinery, but also your brand. That’s one more way we help you build profits you can sink your teeth into. We don’t just make industry run, we make it fly. Visit mobilindustrial.com for more.

© 2011 Exxon Mobil Corporation The Mobil logotype and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.

TECHNOLOGY S O U R C E B O O K

LABEL PRINTER/APPLICATOR Designed for moderate- to high-speed labeling to the top, side or bottom of a product, the Tharo PA500w wipe-on label printer/applicator prints and applies over 100 labels/ min. A product sensor and controller ensure accurate label placement on the product, while a wipe-on brush assures proper adhesion to both smooth, flat surfaces and uneven surfaces. Tharo Systems, Inc.; 800-878-6833; www.tharo.com

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DETECTION PERFECTION

847- 419-XRAY (9729)

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October 2011 | Food Engineering | www.foodengineeringmag.com

RINSING MACHINE The Gamajet Intrepid low-flow, fullcoverage tank rinsing machine offers validatable tank rinsing without the use of chemicals. The unit utilizes a “directdrive” design, applying concentrated streams in a complete 360º pattern with no gear reduction. It incorporates a sanitary design, including FDAcompliant materials, self-cleaning and draining capabilities and a high-polish, sanitary finish. Average operating conditions are between 10 to 80psi and 5 to 20 gal./min. Gamajet Cleaning Systems; 877426-2538; www.gamajet.com

POWER SUPPLIES Pepperl+Fuchs VAN-115/230AC-K19 AS-Interface Class II power supplies are 90.5% efficient to minimize power loss and limit the need for enclosure cooling. A 42mm-wide design enables stacking the power supplies side by side to reduce the size of their enclosure. They support input voltages from 85 VAC to 264 VAC, and deliver up to 2.8 A output. A PowerBoost feature can deliver a temporary output power increase up to 3.2 A. An LED display provides visual status indication. Pepperl+Fuchs, Inc.; 330-486-0001; www.pepperl-fuchs.us

TECHNOLOGY S O U R C E B O O K

LIFT CHECK VALVES Designed for EN and ASME standards, Spirax Sarco LCV3 (cast iron), LCV4 (carbon steel), LCV6 (stainless steel) and LCV7 (SG iron) lift check valves can be used for a range of applications. The check valves prevent the reverse flow in pipelines carrying most types of liquids, steam and gas, and prevent pressure surges associated with hydraulic forces such as water hammers. Spirax Sarco, Inc.; 800-883-4411; www.spiraxsarco.com

S O N I C

VT

TM

DRYER

Huge increase in production time for tanks, blenders & totes

COOKER-COOLER Available in standard sizes from 50through 400-gal. working capacity, the Chester-Jensen cooker-cooler cooks, cools and super blends any pumpable food product, all within one unit. The stainless steel cone bottom cooler-cooker employs dual agitation; the entire cone bottom has a heat exchanger surface. Typical compatible products include gravy, beans, pizza, sauces, pastry and pie fillings, jellies and jams. Chester-Jensen Co., Inc.; 800-6853750; www.chester-jensen.com

TA N K

P AT E N T E D

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D-I-P

D R Y - I N - P L AC E

TECHNOLOGY

160°F pressurized high volume air without heaters 50 to 1000 ft3 tanks dry in 30 minutes or less

3 to 50Hp Sonic blowers based on tank size In-line HEPA filter delivers sanitary air Push button controls

LASER MARKING SYSTEM The Telesis EVC diode-pumped laser marking system can mark on-the-fly at high speeds without burn through on delicate foils and with contrast on various plastics; it also marks on chip boards, plastic bottles and other materials without consumables or ecology issues. It has a Q-switched Nd: YVO4 end-pumped laser design with a remote fiber-coupled diode pump source, and can operate in industrial environments where shock, vibration and dust are a concern. Features include a deep focal tolerance, high-quality small beam diameter, integrated PC with touch screen interface, Merlin LS AMI scan-and-go software, quick-posts and encoder controls. Telesis Technologies Inc.; 724-7330522; www.telesis.com

CONNECT OUR VT TANK DRYER PUSH THE START BUTTON AND WALK AWAY

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AIR SYSTEMS

800-82-SONIC asksonic@sonic airsystems.com www.sonic airsystems.com

www.foodengineeringmag.com | Food Engineering | October 2011

31

Visit us at Booth #1356 Process Expo Show

TECHNOLOGY S O U R C E B O O K

INNOVATIVE STEAM SOLUTIONS Worldwide Boiler Energy Savings: $134-Million! Since 1930, Clayton Industries has taken the lead in steam generating equipment design, manufacturing and service. With an ever-growing diverse and unique line of steam generators, they’re used in a broad range of major industries worldwide.

Here’s what makes Clayton your best choice:

SPIRAL BELTS USDA accepted for meat and poultry, the Ashworth Advantage lotension plastic spiral belt has an increased open area that reduces dwell times and energy consumption. The ExactaStack drop-in replacement belt for self-stacking spirals is available in all widths, tier heights and mesh configurations for spliced-in sections and complete self-stacking belt replacements. It is also available with integrated Advantage modules for a selfstacking spiral belt with a plastic overlay suitable for sticky product applications. Ashworth Bros., Inc.; 800-682-4594; www.ashworth.com

• High Productivity – Clayton Steam Generators are in 18 sizes that range from 10 to 1,000 bhp and with design pressures from 15 to 3,000 psi. They start up and stop quickly, assuring a consistent supply of dry clean steam with no wasted energy.

tator promotes bulk flow and uniform batch temperature, feeding the disperser blade with fresh product while constantly scraping the vessel surfaces. Sanitary designs include special seals, polished wetted parts and sanitary connections. A range of control options are available, from simple variable frequency drives to fully integrated PLC recipe systems. Charles Ross & Son Company; 800243-ROSS; www.mixers.com

• Space Efficiency – Clayton’s exclusive vertical design allows for a space saving very small footprint. • Safety – All Clayton Steam Generators, including its signature Sigma-FireTM series, are 100 percent explosion-proof! • Energy Efficiency – Being more efficient than any other boiler designs, Clayton Steam Systems consistently provides significant energy savings. • Clayton Steam Boilers are built to last! Our expert team of engineers and technicians provide 24/7 service and maintenance assistance. Please contact us or visit our website to learn more.

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

REUSABLE PLASTIC PALLET

DUAL-SHAFT MIXERS Engineered for processing pastes, gels, suspensions, slurries and other viscous formulations, Ross dual-shaft mixers are composed of 2 independently driven agitators working in tandem. A highspeed disperser draws powders into the liquid batch through a vortex and disperses any lumps and agglomerates, while a low-speed anchor agi-

The ORBIS 40-in. x 48-in. reusable plastic grocery distribution pallet is nestable, with a nest ratio that optimizes space in standard 53-ft. trailers. Designed to store, ship and handle product throughout the grocery supply chain, it has an anti-skid surface that holds cases and boxes in place in transit and at retail. Smooth and non-porous, it resists absorbing moisture or odors. Its all-plastic construction ensures dimensional consistency and repeatable performance during its entire service life. ORBIS Corporation; 888-307-2185; www.orbiscorporation.com

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

Openings at Tetra Pak Processing: Product Manager — Mixing Technology Product Manager — Flow Equipment Who Knew? Tetra Pak is the largest supplier of Processing and Packaging Solutions to the Global Food Industry Check the numbers! One Tetra Pak is the largest industrial group providing equipment and turn-key projects to the food industry. 70 Over 70% of the milk and Ice cream consumed in the world is processed on at least one piece of Tetra Pak processing equipment. 90 Over 90% of the cheese consumed in the world is made on Tetra Pak equipment. 5,000 Tetra Pak employs over 5,000 engineers around the globe to design, manufacture, install and service food processing and packaging equipment. Disciplines covered are mechanical engineering, process engineering, controls and automation, food science, etc. 165 Tetra Pak is present in 165 countries, with Processing USA being one of the fastest growing markets.

Please visit us and apply at www.tetrapakprocessing.com

Complete Processing. Innovative Solutions. Visit us at www.tetrapakprocessing.com or directly; [email protected] 800-806-9675

PULSE CONTROL The Omega PCM5 series pulse control module converts a 4 to 20 mA signal from a process/temperature controller or computer to a time proportional Openings_Ad_V1.indd 1 output. Supporting single-phase 50 or 60 Hz operation, the module mounts directly onto a single 3 to 32 VDC Input SSR. The CE-compliant unit tolerates inputs less than 4 mA. It is suitable for various applications in the food processing industry. In my facility, having pumps Omega Engineering, Inc.; I can count on is important. 800-TC-OMEGA; www.omega.com

DON’T SETTLE FOR “GOOD ENOUGH”

Downtime is not an option. X-RAY-DETECTABLE PLASTIC Röchling Polystone M XDT X-raydetectable UHMW-PE is a traceable plastic, designed for machined parts for filling, sorting and packaging machinery. It can be detected with a particle size as small as a 3mm cube. Running at speeds up to 250 ft./min., the plastic can be detected and automatically sorted to a product hold area for further inspection. It works with various types of packaging including metal cans, plastic and composite containers and glass jars. Röchling Engineering Plastics; 704-922-7814

I need quality sanitary transfer equipment that can pump anything from purees to peanut butter –

Graco SaniForce® is my only choice. I know my business and my pumps, and I will not settle for anything less than the best. Contact Graco today:

1-877-844-7226 www.gracosaniforce.com

9/29/11 1:12 P

TECHNOLOGY S O U R C E B O O K

HIGH-SHEAR MIXERS Silverson high-shear mixers hydrate and disperse gums and thickeners, disintegrating agglomerates and exposing an increased surface area of the powdered ingredients to the surrounding liquid. They eliminate the need to premix preparations of gums and thickeners by combining them with other dry ingredients or dispersing them in a nonaqueous phase to facilitate hydration. Silverson Machines, Inc.; 413-525-4825; www.silverson.com

CEIA ‘nose’ metal detection Only CEIA MS21 multi-spectrum metal detectors use multiple frequencies simultaneously. All other metal detectors use only one frequency at a time. With more detection “noses” on the job, CEIA provides the world’s most sensitive metal detection without product effect errors. Call today for a CEIA demonstration using your toughest products!

Next best metal detector

CEIA MS21

DUAL-HEAD PRINTER With 2 print heads that can run independently or in tandem, the Videojet 1610 dual-head, small-character ink jet printer meets a range of applications, including those that require printing on 2 locations on a single product or on multiple lanes on a traversing unit. It can print up to 5 lines of high-resolution code per print head at speeds up to 960 ft./min. Both print heads feature a Clean Flow design that reduces ink buildup on the print head. Videojet Technologies Inc.; 800-8433610; www.videojet.com

METAL-DETECTABLE THERMOPLASTIC

800 227 5980 / 510 259 0500 [email protected] www.heatandcontrol.com

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October 2011 | Food Engineering | www.foodengineeringmag.com

Made from FDA-, USDA- and 3A Dairy-compliant components plus a special additive, Ensinger TECAPEEK ID thermoplastic is visible to standard metal detection systems. Chemical resistant and capable of retaining its flexural and tensile properties at temperatures up to 482°F, it is suitable for a variety of applications in the food industry, such as high-temperature kettle scraper blades. Ensinger Inc.; 800-243-3221; www.ensinger-inc.com

TECHNOLOGY S O U R C E B O O K

MECHANICAL TRAY FORMER The Eagle VASSOYO all-mechanical tray former can run a variety of trays including standard end slot, side slot and clam shell, with or without a lid, at rates up to 40 trays/ min. A built-in changeover system changes from one size to another in minutes; with the extended hopper option, the hopper can be loaded for non-stop production. The former features a heavy-duty, welded steel frame and a mechanical low-maintenance drive. Eagle Packaging Machinery LLC; 305-622-4070; www.eaglepm.com

BATTER DEPOSITING SYSTEMS

WE DELIVER SOLUTIONS FOR ALL YOUR FOOD HANDLING PRESSURES. CONVEYOR OPENS IN SECONDS WITHOUT TOOLS 100% ACCESSIBILITY FOR DAILY CLEANING CLEANS UP 2X FASTER THAN COMPETITION

Call 800.397.8664 or visit www.dorner.com/food

See Food Master, p. 53

36

October 2011 | Food Engineering | www.foodengineeringmag.com

Hinds-Bock automatic loaf cake and muffin batter depositing systems provide automatic pan oiling with single- or multiple-piston depositors; automatic paper liner and foil denesters are optional. Designed with a dry ingredient depositor for nut pieces, chocolate chips, sugar, dry streusel and other flowable dry toppings, the systems can deposit large, delicate particulates damage free. Automatic swirling machines for 2-flavor marble loaf cakes are also available. Hinds-Bock Corporation; 877-2925715; www.hinds-bock.com

BATCH CONTROLLER Adhering to the ISA SP-88 Batch Standard, the Mettler-Toledo IND780batch standalone batch controller can be used for single or multi-scale batching applications. It provides both manual (materials added by hand) batch operation or fully automated (machine-controlled) batching control. It features PC software for recipe management, order management and historical reporting; track and trace functionality; integration of Mettler-Toledo Qi material process control; Zone 2/22 Class 1 Division 2 hazardous area approval; multi-language user interface; graphic visualization of batching system status; and IP69K environment protection. Mettler-Toledo, Inc. 614-438-4511; www.mt.com

“Now we can mix high viscosity emulsions 600% faster.” The Ross PreMax is the first batch rotor/stator mixer that delivers both ultra-high shear mixing quality and high-speed production. In side by side tests, the PreMax produces thickened dressings and sauces much faster than a traditional high shear mixer.

John Paterson PreMax Inventor Employee Owner

With a patented, high-flow rotor/stator design, the PreMax also handles viscosities far beyond the capacity of ordinary batch high shear mixers. In many applications, this can eliminate the need for supplemental agitation.

Contact Ross today to arrange a no-charge test in our laboratory. Call 1-800-243-ROSS Or visit mixers.com

The PreMax with a Delta generator operates with a tip speed of 5,000 fpm and handles viscosity up to 50,000 cP.

*Patent No. 6,000,840

TECHNOLOGY S O U R C E B O O K

clear. safe. solutions. Clarion provides the most highly refined white oils available to help protect your facility from contamination, equipment failure and downtime. EXPERIENCED We have a 40-year history of processing white oils and continue to redefine the leading edge of industry innovation. SECURE As an established national manufacturer, we know the importance of a strong supply chain: When you need our white oils, you’ll be able to get our white oils. COMPLETE Clarion Food Grade FR Fluid Clarion Food Grade White Mineral Oils Clarion Food Machinery Grease, No. 2 Clarion Food Machinery A/W Oils Clarion Food Machinery Gear Oils Clarion Food Machinery HT EP Greases Clarion PM Hi-Temp Food Machinery 100 Greases Clarion Chain and Trolley Lube

ROTARY AIRLOCK FEEDER Suited for dairy, food, baking and powder coating plants, the Meyer Klean-In-Place rotary airlock feeder is a special-purpose valve that incorporates a built-in device that automatically reestablishes the close dimensional tolerances between the rotor and housing and a safety interlock switch. No tools are required to remove the head plate; 4 slide bar supports, using linear bearings, provide support of the rotor while it’s pulled out. Available with square or round flanges, standard airlock options and USDA and sanitary construction, the valve meets 3A Sanitary Standards. Wm. W. Meyer & Sons, Inc.; 847-918-0111; www.wmwmeyer.com 120 in. with virtually any geometry including narrow cross-sections and close hole spacing, the gaskets and seals are manufactured with tolerances to +/-0.005 in., depending upon material. Interstate Specialty Products, Inc.; 800-984-1811; www.interstatesp.com

COMMITTED Our technical field support team is able to optimize your operation by creating custom solutions. RELIABLE Clarion Food Grade Lubricants are NSF H-1 registered and Kosher certified.

INLINE PROCESS RHEOMETER

To learn how Clarion can refine your operation, call 855-MY-CLARION or visit clarionlubricants.com.

GASKETS AND SEALS Offered in a range of configurations for preventing contaminants or light from entering into various types of equipment and instrument enclosures, Interstate custom gaskets and seals feature digital die-less cutting. They can be made from PTFE, expanded PTFE, medicalgrade USP Class 6 silicones, open- and closed-cell foams, high-performance elastomers and other materials to match specific application requirements. Available in sizes from 1-in. sq. up to 60 in. x See Food Master, p. IFC 13, 36-41

Providing inline, continuous measurement of fluid viscosity for process control and monitoring applications, the KROHNE Viscoline inline process rheometer can be used for a variety of Newtonian or NonNewtonian applications, including emulsions, ketchup, yogurt, sauces, cheese and more. No mechanical process modification is required for accurate viscosity measurements. The meter has all-stainless steel construction and no moving parts. It features continuous measurement with analog or digital outputs, and has a repeatability of 0.2% and resolution to 0.1cP. The standard hardware configuration features 2 inline mixer assemblies, a control box and an operating and maintenance manual. KROHNE, Inc.; 800-FLOWING; www.krohne.com

October 2011 | Food Engineering | www.foodengineeringmag.com

IMAGINE A WORLD WITHOUT CONTAMINATION OR DOWNTIME.

VISIT US AT THE PROCESS

EXPO — NOV. 1-4 — BOOTH #1740

We know how hard you work to meet demand and stay competitive. But no matter how meticulously you service your equipment or how much skill your workforce acquires, accidents happen. Something as simple as a ruptured hose can lead to lost profit, missed deadlines and even e damaged reputations. That’s why we created Clarion Food Grade Lubricants. This full line ne of of NSF H-1 regist registered food grade products including oils, greases and fluids has been sp pecifically formulated to iinhibit nhibit oxidation and provide anti-wear properties to safeguarrd your operation and givee your bottom line the security it des deserves. ser

FOOD GRADE

clear. safe. solutions.

TECHNOLOGY S O U R C E B O O K

SQUARE SPRING LATCHES

SILOS Mueller Model SV silos have a vertical design that allows maximum product storage in a minimum of space; a stud-welded, circumferentially banded bottom construction protects against fatigue. A fully CIP-able horizontal agitator meets the requirements of 3A Sanitary Standard 22 and the USDA Dairy Grading Branch Survey Program. Shop-fabricated silos through 70,000 gal. and field-erected silos through hundreds of thousands of gal. are available. Paul Mueller Company; 800-MUELLER; www.muel.com

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October 2011 | Food Engineering | www.foodengineeringmag.com

Engineered for use in applications where less precise positioning/locking is required, Winco GN 722.2 square spring latches with flange for surface mounting ensure functional safety when exposed to dirty or dusty environments. The spring latches are used when indexing pins need to be retracted; an indexing pin retracts by turning the latch up the cam slope by 180°. A lock notch holds the latch in both positions. The flange has 2 holes for mounting that can accommodate metric DIN 933/931 hex cap screws or DIN 912 socket cap screws. The RoHS-compliant latches are available with the latch position either right-angled or parallel to the mounting holes. J.W. Winco; 800-877-8351; www.jwwinco.com

TECHNOLOGY S O U R C E B O O K

BAGGER CATCH CLOTHS Designed for installation under conveyors in the food processing and baking industries, AFF 18-gauge vinyl catch cloths prevent errant product from dropping onto other lines or being transferred throughout the plant. Catch cloths with custom sizing and grommet placement to fit beneath any conveyor are available. The company also duplicates straights, 45° and 90° turns, or S-curves; adds dump chutes or funnels for high-volume applications; and provides catch cloth installation service. American Fabric Filter Co.; 800-367-3591; www.americanfabricfilter.com

NORD SURFACE PROTECTION REINVENTED!

Designed for premade polyethylene and laminated wicketed bags and operating at speeds up to 35cpm, the WeighPack VS bagger automatically draws a bag, waits for it to be filled and then transfers it to interface with a horizontal sealer or twist tying machine. It can handle bag lengths of 6 to 20 in. and 6 to 14 in. Available in left-to-right and right-to-left configurations, the bagger has a heavy-duty frame construction and adjustable wicket pins. Options include a plunging funnel, bag support table and foot pedal for semi-automatic operation. WeighPack Systems Inc.; 888-934-4472; www.weighpack.com

NSD TupH, A BREAKTHROUGH IN PROTECTION AT A MOLECULAR LEVEL. At last it’s here, a cost-effective and weight-saving alternative to stainless steel for use in the harshest environments. NORD has redefined surface protection. NSD TupH is a true innovation in corrosion resistant cleanable sealed surfaces. Molecular conversion of the aluminum alloy provides our drive equipment with all the protection your application demands. All of this at a fraction of the price you have been forced to pay for stainless steel. Introducing NSD TupH, the better solution you have been asking for is finally here. You can immediately start saving big money on protection without compromising quality. Contact us today and find out how you can profit from NORD reinvention.

www.nord.com INNOVATION BEYOND THE ORDINARY www.foodengineeringmag.com | Food Engineering | October 2011

41

Shaft Alignment

TECHNOLOGY S O U R C E B O O K

& Geometric Measurement

including solid shafts with and without keys, and hollow output shafts with and without keys. Output shafts are available in carbon and stainless steel. Motors from other suppliers can be fitted using an adapter with a backlash-free coupling that features thermal length compensation. STOBER Drives, Inc.; 606-759-5090; www.stober.com

Rotalign® ULTRA

Vibration Analysis

& Balancing

h WatcOS E VID ine Onl

VIBXPERT® II

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

305-591-8935 • www.ludeca.com

See Us at Process Expo Booth #1722

LED LIGHT EMITTER The Larson Magnalight LED10W-6R-HT LED light emitter offers high light output and a combined handle and magnetic mounting system to provide mobility and secure mounting on any surface that accepts a magnet. Capable of operating on any voltage from 9 to 50 VDC, the unit can be used anywhere a common 12-24 volt DC current source is available. It produces 5,400 lumens and is capable of throwing a light beam over 600 ft. in length. An extruded aluminum body housing 6 Seoul Z-Power 10 watt LEDs provides IP68-rated waterproof protection for the internal electronics; unbreakable polycarbonate lenses protect the LED and reflector assemblies. Stainless steel hardware resists corrosion and the elements. The light emitter is available in spot or flood configurations. Larson Electronics; 800-369-6671; www.magnalight.com

BEVEL GEAR UNIT A compact right-angle drive, the STOBER KL helical bevel gear unit is suitable for packaging, filling, conveying, general automation and washdowns. Input speeds up to 6,000rpm are possible in cyclic operation; the torque range is up to 65 Nm. A right-angle gear unit on the output side offers various options for output shafts and mounting methods,

MEMBRANE SWITCHES APEM customized membrane switches can be produced in a variety of designs, colors and lighting solutions. With lowprofile, space-saving designs that adapt to any project, the ergonomic switches can be made with either tactile feedback through sound and light indication or nontactile. They feature flexible tail termination designed to connect directly to electronic equipment. Made for moderate to harsh conditions, including water immersion, electromagnetic interference, UV exposure, grease and gasoline, the switches meet IP65, IP67 and NEMA4 standards. APEM Components; 978-372-1602; www.apem.com

STAGING BUFFER Accommodating multiple load sizes, the Dematic Multishuttle Flex staging buffer accepts totes, trays and cartons. It expands and contracts to accommodate the size of the load, automatically adjusting on the fly as it travels to a storage location, so the extractor device is set to accept the load. The buffer has a load width range of 8 to 24 in. and a load length range of 6 to 34 in. The unit can provide single or double deep loading in the rack structure. Dematic; www.dematic.us

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

Take a Fresh Approach with The Shelf Life People.

CLEANING INJECTORS Spraying Systems TankJet B and BX injectors transform steam and cold water into high-pressure, high-temperature liquid feeds for tank cleaning machines and customdesigned nozzle manifolds. When used with cold, lowpressure city water and existing plant steam, the injectors are nonintrusive and can eliminate the need for pumps and heat exchangers. A liquid control valve siphons chemicals or detergents into the hot water stream. An overflow valve prevents accidents. The TankJet B injector can be used for liquid discharge capacities up to 34gpm (129 l/min.); the TankJet BX injector can be used for liquid discharge capacities up to 110gpm (416 l/min.). Spraying Systems Co.; 630-665-5000; www.spray.com

AC SERVO An alternative to traditional stepper technology, the Yaskawa Junma AC servo has a plug-and-play design that requires no parameter settings or gain adjustments. The servo accepts a pulse reference input from the host controller or PLC. System parameters are set on system power up, machine load inertia is calculated automatically, and tuning gains are adjusted dynamically, even when the load changes. Adaptive tuning and vibration suppression functions maintain steady positioning. Other functions include jogging, homing to marker pulse, electronic gearing and torque limiting. The RoHS-compliant servo conforms to UL and CE industry standards. Yaskawa America, Inc.; www.yaskawa.com

www.foodengineeringmag.com | Food Engineering | October 2011

Take shelf life to the next level with our new EQ-70 gable top filling machine. Developed specifically for mid-size volume markets, the EQ-70 is designed with our exclusive ELL® features to maximize the shelf life of milk, specialty milk products, liquid egg products and still beverages. t
Preserve freshness: Environmental control features and carton treatment maintain product quality t
Maximize production: Servo-driven features simplify operation t
Gain flexibility: Quick and easy changes to fill volume, carton heights t
Reduce downtime: Easy to operate and maintain Want to apply our fresh approach to your next product? Call us today . . . because we’re The Shelf Life People.

See us at Booth S-2448

$FEBS
3BQJET
*PXB
t
 www.evergreenpackaging.com

Optional SPOUT-PAK® closure system available. ©2011 Evergreen Packaging Inc. All Rights Reserved. ELL is a registered trademark of Evergreen Packaging Inc. SPOUT-PAK is a registered trademark of Evergreen Packaging International BV.

TECHNOLOGY S O U R C E B O O K

WASHDOWN MOTOR Available with 1140, 1725 and 3450rpm ratings, the Bluffton HydroDuty washdown motor has a C-face with keyed shaft and comes with either a rigid base or no base. With a stainless steel exterior, moisture-managed conduit box, water-tight motor lead connections and water-resistant breather vent, the motor protects against moisture intrusion at every possible point; a center cavity drains moisture away from the motor face, and 3-stage seal system protects the bearings. The motor has received approval from the Underwriters Laboratory and meets National Electrical Manufacturers Association Standards 56C, 145TC and 184TC. Bluffton Motor Works; 800-579-8527; www.blufftonmotorworks.com

PROCESS CONTROL SUITE The Honeywell vendor-neutral process control suite allows plant operators to centrally monitor and control both Honeywell and non-Honeywell process control systems. Suitable for all industrial applications, the suite can span multiple Advanced Process Control technologies and multiple processing facilities. It includes 3 software products: Honeywell Loop Scout to identify and correct poorly performing control loops; Honeywell Profit Expert for multivariable monitoring of the Honeywell Profit Controller; and Control Performance Monitor to monitor, identify, diagnose and remedy regulatory and APC asset issues. Honeywell Process Solutions; www.honeywellprocess.com

5''75#6 241%'55 ':21 $116*

DEEP FROZEN VANS Used for the transportation and delivery of perishables and temperature-sensitive cargo, the Stoops Glacier King Sprinter van can transport deeply frozen cargo at temperatures as low as -20ºF; it is also suitable for fresh refrigerated or lightly frozen products. Multi-temperature compartments, electric standby/shore power, heat capability and unique shelving packages are available. Stoops Freightliner; www.stoops.com

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

SHATTER-RESISTANT CFLS If accidentally broken, Shat-R-Shield CFL PARs, globes, reflectors and twists contain virtually all the glass, phosphors and mercury within their clear, skin-tight plastic coating. The Shat-R-Shield silicone safety coating is optically clear, and blocks over 97% of damaging UV light. The shatter-resistant fluorescent CFLs meet safety regulations in the US, Canada and Mexico, including FDA, OSHA, ASME and CFIA. Shat-R-Shield; www.shatrshield.com

SHRINK WRAPPERS Designed to interface with existing tray packers, including the Douglas’ Invex and Axiom at speeds up to 40 trays/min., Douglas VS Series shrink wrappers use single-film roll technology. An optional print-registered film control enhances package appearance. Heat tunnel technology ensures minimal graphic distortion and a tighter wrap. Douglas Machine Inc.; 320-763-6587; www.douglas-machine.com

CONVERSION KIT The Spee-Dee Servo 3600 auger filler conversion kit transforms an existing clutch/brake unit into a highperforming servo system. In the conversion process, the column, head casting, agitator system, hopper and cover, and auger tooling of the clutch/brake unit are all retained. A 7-in. full-color touch screen operator interface enables controlling and changing fill parameters while the machine is running. An Allen-Bradley PLC comes standard in the kit. Spee-Dee Packaging Machinery, Inc.; 877-375-2121; www.spee-dee.com

www.foodengineeringmag.com | Food Engineering | October 2011

See Food Master, p. IFC 14

TECHNOLOGY S O U R C E B O O K

46

PH ELECTRODES

LIQUID LEVEL SENSORS

Providing accurate and stable pH measurement changes in dynamic process environments, Sensorex research-grade pHASE pH electrodes are designed for variable temperature operation process testing. Offered with either epoxy or glass bodies, they have built-in double junction references that prevent the silver ions from contacting product samples. Electrodes with epoxy bodies feature removable guards to protect the pH bulb from breakage; electrodes with glass bodies feature have spherical bulbs. Sensorex; 714-895-4344; www.sensorex.com

Gems miniature ELS-950M Series Electro Optic liquid level sensors have a brass housing to perform in harsh environments, maintain integrity in temperatures ranging from -40°F to 230°F and pressures to 250psi. The sensors feature an over-molded electronics insert, TPE-insulated wires and a fluorocarbon O-ring seal for a watertight assembly. UL and CE approved to EMI standards and shock and vibration tested to MIL standards, they are IP66/67 and RoHS compliant. The sensors are available in 5 or 12 VDC models. Gems Sensors & Controls; www.gemssensors.com

October 2011 | Food Engineering | www.foodengineeringmag.com

STEAM TUNNEL Fabricated from #304 stainless steel, the Axon ThermoJet heat-shrink tunnel features a large heat zone where 2 steam manifolds and multi-position mandrels direct steam for shrinkage of a label, sleeve or tamper band. It accommodates containers 1 to 7.75 in. in diameter and with a maximum height of 12 in. The standard unit comes with a cantilevered stand that facilitates moving the tunnel. Axon; 800-598-8601; www.axoncorp.com

See Food Master, p. 124-125

www.foodengineeringmag.com | Food Engineering | October 2011

47

TECHNOLOGY S O U R C E B O O K

HOSE FITTINGS

VACUUM CONVEYING UNIT

AdvantaPure 316L stainless steel hose fittings offer a 15 Ra or better finish for smooth, noncontaminating flows; 8-sided designs for tightening in restrictive installations; and radiused edges. Sanitary, pipe thread, and cam and groove styles are available; most are 3A approved. AdvantaPure over-molded triclamp ends for PVC, TPE and TPR tubing are injection molded from USP Class VI Hytrel or polypropylene. Offered in mini and standard styles like silicone and AdvantaFlex, they can be used for food, beverage and dairy applications. AdvantaPure; 888-755-4370; www.advantapure.com

The Volkmann VS200-F1 16-in. high vacuum conveying unit conveys capacities up to 500 lbs./hr. Used for granular products, the low-profile unit features an MX 360 vacuum pump capable of vacuum levels as low as 27-in. hg vacuum for lean, dense or plug flow conditions. It features a quick-release QX-style filter, full modular 316L stainless steel construction, 8-in. diameter full-bore body and full-bore discharge valve free from operating parts within the product stream. The unit meets ATEX certification for use in explosion-proof areas. Volkmann, Inc.; 609-265-0101; www.volkmannusa.com

We Protect You!

USDA Certified Bunting® was the first company to earn, USDA, AMS Acceptance for our products. Our specially built food grade or sanitary-grade magnetic separators help you meet today's increased marketplace demands.

To ensure the quality of your products and to protect your reputation, Trust Bunting!

Avoid Contamination November 1-4, 2011 Chicago, Illinois McCormick Place, South Hall Booth #3640

Plate Magnet

Bunting® products exceed governmental requirements for safer and purer food, pharmeceuticals and chemicals. BUNTING®...your premier choice for g p q magnetic separation equipment.

Grate Magnet

ut Our Ask Abo ETIC MAGN ION T SEPARA UDITS A T PLAN

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

800-835-2526 316-284-2020

or

buntingmagnetics.com

(outside USA or Canada)

Email: [email protected]

magnets

|

separation

|

conveyors

See Food Master, p. 25

|

metal detection

|

cylinders

|

flexible dies

©2011 Bunting® Magnetics Co. BUNT-091211-2

48

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

POWER FACTOR CORRECTION The StacoVAR mini automatic power factor correction bank maintains a desired power factor level by using a microprocessorbased controller to adjust to system load conditions. Metalized polypropylene dry-type capacitors inside the compact enclosure incorporate an overpressure device and discharge resistor safety system; capacitor-rated contactors with damping resistors reduce back-to-back switching currents. UL listed, the unit is suitable for a variety of applications including food and beverage processing, water and wastewater treatment, and manufacturing and industrial facilities. Staco Energy Products; 866-266-1191; www.stacoenergy.com

VERTICAL LIFT The TKF Valu-Lift light-duty, 4-strand, continuous vertical lift conveyor handles cartons and other smooth-bottom unit loads up to 50 lbs. The platform design consists of lightweight, interlocking molded polymer flights with steel connecting pins. Standard net lifting heights range from 8 to 14 ft. with customized heights available. The conveyor’s maximum unit load is 21-in. long, 16-in. wide and 22-ft. high with a weight of 50 lbs. The minimum unit load without special transitions is 10-in. long x 4-in. wide x 1 1/2-in. high with a weight of 3 lbs. Standard safety features include a 24 volt DC control, current sensing relay and totally enclosed shroud-type tunnel guards. TKF, Inc.; www.tkf.com

DOCK DOOR Designed for use with vertical storing dock levelers, the TKO VertiCool door has a 4-in. thick R-23 insulated panel that mirrors the insulated wall panel for thermal protection and 48-in. panel heights for energy efficiency. Dual compression side seals mounted to the door panel prevent damage and maintain effectiveness. A heavyduty polymer thermal brake track runs the full opening height, while dual overlapping header seal and compression loop bottom seals maintain a consistent seal around all sides of the door. TKO Dock Doors; 877-408-6788

T H E P R I NC I P L E B EH I ND C L EAN . s Seal-less pump design s Self priming (run-dry capable) s Low shear s Low pulsation s Low maintenance / self adjusting

mouvex.com

6AN"UREN3Ts'RAND4ERRACE #! 

www.foodengineeringmag.com | Food Engineering | October 2011

49

TECHNOLOGY S O U R C E B O O K

COMBUSTION ANALYZER The E Instruments BTU1100-HE portable combustion analyzer high-efficiency kit has an incoming Air Smart probe and field-replaceable sensors. It includes a built-in non-thermal printer, manometer, thermometer (ambient and flue gas) and CO leak detector; dual 9-ft. hose and 12-in. probe (gas and draft at the same time); rechargeable battery; and AC charger. It features unbreakable metal connections and a “boiler room” design. E Instruments International; 215-750-1212; www.e-inst.com

KEY ADAPTOR Fortress Interlocks E1 extracted key adaptor ensures the door to hazardous machinery cannot be opened without removing the safety key, and cannot be restarted until the key is returned. It traps the actuator in the head unit until the key is removed, which allows the “gate” to swing over the keyhole. While the actuator remains out of the head, the gate remains over the keyhole, preventing the key being returned to the lock. The adaptor can be stacked or combined with other adaptors; up to 5 key adaptors can be used in one configuration. It is suitable for hinged or sliding door applications. Fortress Interlocks; 859-578-2390; www.fortressinterlocks.com

MATERIAL MASTER ™

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NEW Patented design delivers superior performance Choosy about bag handling? We hear you. Take a closer look at the features of our Material Master Discharger: i

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Ask about our complete line of drum and container dumpers, bulk bag ¿llers and bulk bag conditioners.

50

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

NEMO® Sanitary Pumps „ Flow rates up to 600 gpm „ Pressures up to 360 psi „ Gentle handling of food products „ High and low viscosity capabilities „ 3A, EHEDG and QHD certified „ Sanitary and Aseptic designs available „ Precise metering

NETZSCH, the world market leader with 60 years of experience and over 500,000 progressing cavity pump installations worldwide. With sales, production and service on 6 continents ensuring customer support to provide

AIR CONDITIONERS

Pumps & Systems — Solutions you can trust

Offering filterless operation and features designed for energy efficiency, McLean SPECTRACOOL NARROW air conditioners deliver cooling within enclosures to protect vital electronics. The units fit on a 12-in. enclosure; they also accommodate wall- and floor-mount cabinet styles. A specially coated condenser coil resists dust buildup and protects against corrosion. Pentair Technical Products; www.mcleancoolingtech.com

Learn more.

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acting standards.

F i h lii d on our expertise i iin llubricant bi h l d our For over 50 years, companies have relied technology and commitment to research and development of innovative lubrication solutions. It’s for th these reasons that all JAX lubricants are compounded with the finest raw materials and formulated by 800.782.8850 t iindustry’s the d ’ fforemost engineers i l exceed d our own hi h d d b l surpass but also to not only high-standards, www.jax.com your expectations for performance and value. Whe siness, you dem d When it comes to your b business, demand e ll ’ our responsibility ibili to d li hi lless. deliver nothing excellence – iit’s See Food Master, p. 76-77

FEX11074Jax.indd 1

| October www.foodengineeringmag.com | Food Engineering10/11/07 2011AM51 9:50:15

TECHNOLOGY S O U R C E B O O K

SAW/ GRINDERS The Hollymatic HiYield meat saw includes a quick-stop brake that stops the blade within 1 second of shut-off to reduce the risk of injury. Hollymatic grinders feature output rates ranging from 3,000 lbs./hr. up to 9,900 lbs./hr. Various horsepowers and options are available. Hollymatic; www. hollymatic.com

CASE CONVEYORS Intelligrated Accuglide and IntelliQ powered roller accumulation case conveyors provide positive transportation and true zero-pressure accumulation for virtually damage-free handling of a variety of products. Jam detection logic identifies flow inter-

ruptions and command zone shutdowns, while photo-eye visibility eliminates the need for additional system-level eyes. An on-board independent logic controller stores commands to reduce programming requirements and central computer communication. The IntelliQ conveyor is suited for cold room applications; the Accuglide model is available in a stainless steel construction for food and beverage applications, and in a pallet load version for pallet handling applications. Intelligrated; 513-881-5239; www.intelligrated.com

CONTACT SURFACE COATING Sherwin-Williams Magnalux 304 FF flake-filled vinyl ester is approved for food contact surfaces associated with producing, storing and transporting food products. A chemical- and heat-resistant immersion coating, it meets FDA 175.300 for conditions of use D, E and F, covering dry and liquid foods and beverages that are hot filled or pasteurized below 150ºF; room temperature filled and stored, with no thermal treatment in the container; and subject to refrigerated storage, with no thermal treatment in the container. It is approved for food types I, II, III, IVA and IVB, V, VI, VII, and VIII within specific ranges. The coating can be applied with conventional or airless spray equipment on steel and concrete surfaces. Sherwin-Williams; 800-524-5979

Hang up your gloves. A better way to wash and sanitize pallets is right at your fingertips! Standardize your cleaning process with Douglas Washing and Sanitizing Systems® and achieve optimum results time after time-- automatically! Our continuous cleaning tunnel washes for pallets meet the growing demand for a compact, low cost solution that saves water, labor and energy. Features include stainless steel construction, recirculating wash water and self contained water heating. So rely on the industry leader for over 25 years and say goodbye to the time consuming and costly routine of hand washing! See Food Master, p. 54

CALL 800-331-6870

for pricing, literature and specifications. 2101 CALUMET ST. • CLEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX (727) 449-0029 • www.dougmac.com

52

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

ELECTRIC ACTUATORS Hayward CSA-listed EPZ Series industrial electric actuators for small-diameter ball valves are suitable for tight-space applications. They feature on /off jog control capabilities, an aluminum alloy dry powder-coated housing, Thermal Class F motor protection and manual override including lock-out functionality. The EPZ-6 version has a torque output of 55 in.-lb./6 Nm; the EPZ-15 actuator features an output of 135 in.-lb./15 Nm. Both models have an ISO5211 F03/F05 mounting pattern. Hayward Flow Control; 888-429-4635; www.haywardflowcontrol.com

See Food Master, p. 5-7

www.foodengineeringmag.com | Food Engineering | October 2011

53

TECHNOLOGY S O U R C E B O O K

INDICATOR LIGHT LOAD STAND A direct vessel-to-foundation structural member, the KistlerMorse load stand II is suitable for weighing vessels with loads of 100,000 lbs. or more; it is available in sizes from 25,000 to 1,000,000 lbs. per support point. The unit has full UBC wind and seismic ratings. Easy-to-match mounting plates simplify installation. Kistler-Morse; 800-426-9010; www.kistlermorse.com

The Banner K50L EZ-LIGHT indicator light with an audible alarm has a fully sealed body, rated IP67 or IP69K depending on the model. A completely self-contained device, the light requires no controller for operation, eliminating the need for wires. It is unaffected by EMI and RFI interference. Available in 1-, 2- and 3-color models with green, red and yellow LEDs, the light features 5-pin Euro quick disconnect with PNP input. Banner Engineering Corp.; 888-373-6767; www.bannerengineering.com

Ultra Pouch Chilling System Salad Dressings

Soups

Stews

Custards

Puddings

Sauces

Gravy

Tomato Sauce

Cheese

FASTERR CHILLING NG TIMES GENTLE TLE POUCH AGITATION TATION LOWER OPERATING COST FLOOR SPACE SAVING DESIGN 54

October 2011 | Food Engineering | www.foodengineeringmag.com

Come See Us at Booth No. 1448 Phone: (631) 293-2211 • Fax: (631) 293-3788 Email: [email protected] • www.ijwhite.com See Food Master, p. 71

TECHNOLOGY S O U R C E B O O K

Tank Cleaning Devices and CIP Nozzles EXTRUSION LINES Clextral extrusion lines process many cracker styles on a single production line, from traditional cracker styles to multigrain crackers with whole grain nuggets and inclusions, to thin and light crisps, to dipping-strength crackers, to filled bars. The different styles can be processed on the same extruder with easyto-implement recipe modifications and configuration changes. New product development assistance including product concepts, formulation/recipe tests, brand extension design and market prototype production are available. Clextral Inc.; 813-854-4434; www.clextral.com

Reduced Effluent and Reduced Cost

For Rent or Purchasee Contact Butterworth for moree info information: ormation: [email protected] 281-821-7300 www.butterworth.com

www.foodengineeringmag.com | Food Engineering | October 2011

55

TECHNOLOGY S O U R C E B O O K

with hardened metal enclosures, the switches are UL approved for use in Class I, Division 2 hazardous locations, and can withstand temperatures from -40ºC to 70ºC. The switches have 16kV port protection and redundant power inputs for continuous network performance. Red Lion Controls, Inc.; 717-767-6511; www.redlion.net

ETHERNET SWITCHES Offered with 4, 5 or 8 ports, Red Lion NT100 unmanaged Ethernet switches deliver automatic speed, duplex and cable sensing for mission-critical applications in harsh environments. The switches provide high-speed connections to multiple devices over Ethernet, without manual configuration. Capable of autonegotiating 10/100Mb networks and half/full duplex communications, they are equipped with auto-crossing detection that supports standard and crossover Ethernet cables. Constructed

COOKERS/STUFFER Constructed by ASME-certified welders, Mepaco ThermaBlend cookers are intended for large-scale cooking and cooling applications. The Mepaco 420V continuous-vacuum stuffer pulls and maintains full vacuum, gently agitating product in its vacuum chamber to expose more area to deaeration. Mepaco; 920-356-7323; www.mepaco.net

PROCESS EXPO BOOTH #1727 Your Partner in Productivity

Dryers Roasters Ovens Coolers Cookers CPM Wolverine Proctor LLC

CPM Wolverine Proctor LTD

251 Gibraltar Road Horsham, PA 19044 Phone: 215.443.5200 Fax: 215.443.5206 Email: [email protected]

3 Langlands Avenue Kelvin South Business Park East Kilbride Glasgow, UK G75 0YG Tel: 44 (0) 1355.575350 Fax: 44 (0) 1355.575351 Email: [email protected]

www.cpmwolverineproctor.com

| www.wolverineproctor.co.uk See Food Master, p. 44-45

56

October 2011 | Food Engineering | www.foodengineeringmag.com

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TECHNOLOGY S O U R C E B O O K

MIXER MOUNTS Sharpe clamp- and cup plate-mounted portable mixers come with the M5 Quick-Lock mounting system that lets users install and reposition the mixers without tools; ergonomic hand wheels include a hexagonal base to accept an open-end wrench for added leverage. Interlocking wedge components provide enhanced locking force when the wheels are turned by hand. The mounting system is constructed from stainless steel. Sharpe Mixers; 800-862-3736; www.sharpemixers.com

FREEZER CURTAIN WALL An airflow and thermal barrier for blast freezer cells, the Zoneworks sliding blast freezer curtain wall eliminates the need for insulated panel doors. The curtain wall is made of insulated, sliding panels nested in a tubular steel frame; each panel is con-

structed of 18-oz. industrial vinyl fabric surrounding a layer of antimicrobial polyester batting. The panels slide open and closed on a track-and-trolley system. The curtain wall is available in 3 design options: between jambs, single slide or bi-parting. Zoneworks; 800-553-4834; www.zoneworks.com

MEASUREMENT SENSORS Compatible with the Modbus and Profibus network protocols, Raytek MI3 Series infrared temperature measurement sensors can be used in a range of applications requiring digital communication for field devices. The sensors combine an IP65 (NEMA 4) stainless steel sensing head with a separate communication module, and include a variety of sensing head temperature ranges and spectral responses, a standard USB 2.0 digital interface, a fully programmable electronics platform and response times as fast as 20 mS. They offer a choice of scalable 0/4 to 20 mA and 0 to 5/10 VDC analog outputs, or Type J, K, R or S thermocouple outputs, as well as an optional RS485 network interface. Other features include adjustable emissivity, transmissivity, peak hold, valley hold and signal averaging; and configurable inputs for emissivity control, ambient background compensation and trigger/hold input. Raytek; www.raytek.com

Come see us at PROCESS EXPO booth # 816 See Food Master, p. 24 www.foodengineeringmag.com | Food Engineering | October 2011

57

TECHNOLOGY S O U R C E B O O K

PROCESS CALIBRATORS Fluke 750 Series documenting process calibrators calibrate temperature, pressure, voltage, current, resistance and frequency; they have 3 operating modes: measure, source and simultaneous measure/source. A rechargeable Li-ion battery pack provides enough power for an entire shift and can be charged from within the calibrator. The calibrators include 3 sets of stackable test leads, 3 sets of TP220 test probes with 3 sets of extended-tooth alligator clips, 2 sets of AC280 hook clips, a C799 soft case with a clear window that allows full access to the controls and keyboard, a battery charger and USB communication cable. Fluke Corporation; 800-443-5853; www.fluke.com

TUNNEL FREEZER Intended for smaller-volume food processors and start-ups, the Air Products Freshline QS tunnel freezer cryogenically freezes or cools a variety of foods such as meat and poultry, seafood, fruits and vegetables, pasta, dairy products, baked goods and prepared meals. With the freezer, in-process or continuous freezing can be integrated into a food production line, freeing up walk-in freezer storage space. The freezer uses -196°C liquid nitrogen to achieve temperature reduction. The automated control system stores product-specific operating set points. Air Products; 800-654-4567; www.airproducts.com October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

COLLOID MILL Providing the final step in creating a uniform, viscous product for OEMs and contract manufacturers of liquids, creams and gels, the Bematek Z-Series colloid mill features a high-shear inline mixing head that processes emulsions and dispersions through a series of rotors and stators. Fully scalable for applications requiring 10 to 10,000 GPH throughput, the mill includes a variable frequency drive for precise speed control and adjustability. Offered for laboratories, pilot plants and production facilities, it complies with 3A, USDA and FDA standards. Bematek Systems, Inc.; 877-236-2835; www.bematek.com

PIPING SYSTEM Designed for harsh liquid chemical applications, the Asahi Chem Proline crack-resistant polyethylene piping system is made from PE100-RC resin. Including pipe, fittings, valves, leak detection, injection quills and chemical feed skids, the thermally fused system uses no glues and features minimal threaded connections. Its pH capability ranges from one to 14, with pressures up to 150psi and temperatures up to 140˚F. Available in pipe sizes to 4 in. and in single- or double-wall configurations, the system is suited for use in water treatment and chemical process applications using a variety of chemicals including sodium hydroxide, sodium hypochlorite, caustic soda and low concentration acids. It is UV resistant and can be installed above or below ground using socket, butt or electrofusion joining methods. Asahi/America, Inc.; 800-343-3618; www.asahi-america.com www.foodengineeringmag.com | Food Engineering | October 2011

TECHNOLOGY S O U R C E B O O K

CONTINUOUS-DUTY VACUUM CLEANERS Constructed of heavy-duty steel and polypropylene, Nilfisk CFM T-Series 3-phase, continuous-duty vacuum cleaners are engineered for the collection of powders, liquids, dust and debris, even in challenging environments. A manual filter shaker removes caked-on debris from the filter’s surface to maintain the vacuum’s suction power; a release lever lowers the wheeled collection container and acts as a handle for disposal of collected debris. An optional HEPA filter retains 99.995% of particles down to and including 0.18 microns in size. Nilfisk Industrial Vacuums; www.nilfiskindustrialvacuums.com

BATTERY COMPARTMENT Available as an option on Toyota 8-Series 4-wheel AC electric lift trucks in 4,000and 5,000-lb. load capacities, the Toyota 27-in. battery compartment supports jobs with narrow aisle and tight turning radius requirements while maintaining peak capacities at high lift heights. The design accommodates either a 36-volt or 48-volt battery. The 8-Series 4-wheel AC electric lift trucks with the compartment option feature the Toyota System of Active Stability that helps reduce the likelihood of lateral and longitudinal tipovers. An Active Control Rear Stabilizer System and Active Mast Function Controller System work in conjunction to add truck stability. Toyota Material Handling, U.S.A.; 800-226-0009; www.toyotaforklift.com

MECHATRON® 3-A Loss-In-Weight Feeders

Quick, easy product changeover and food safety

SolidsFlow™ USDA Vibratory Feeders

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

See Food Master, p. 3

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

Visit us at Process Expo Booth #4715 60

October 2011 | Food Engineering | www.foodengineeringmag.com

Schenck AccuRate is a unit of Schenck Process

©2009 Schenck AccuRate

TECHNOLOGY S O U R C E B O O K

seal without any adhesive, and can be replaced without special tools. The enclosures can be mounted with rounded stand-off brackets on the back to improve the flow of water around the unit during washdown procedures; using optional hardware, larger enclosures can be mounted on leveling feet and fitted with a wire shelf to assist with cable routing. The enclosures are available to NEMA 4X specifications and with screw covers for smaller, integrated applications or hinged doors for larger installations. Rittal Corporation; www.rittal-corp.com

FLOW WRAPPER

HYGIENIC DESIGN ENCLOSURES Crafted of stainless steel, Rittal hygienic design enclosures feature a smooth surface grain, internal hinges, washable gaskets, locks and no crevices to trap debris or contaminates. Continuous silicone seal door gaskets align with a fitted channel for a tight

Engineered for the packaging of fresh, perishable goods, the Bosch Pack 301 LD flow wrapper has a revolving sealing system that allows for long sealing times to create hermetically sealed seams. A feature that allows processing temperature to be independently controlled on both the top and bottom sealing jaws further ensures seal quality. The system automatically detects products located between the cross-sealing jaws, ensures these packages are not sealed and rejects them after the sealing station. Capable of producing up to 150 packages/min., the wrapper can also integrate modified atmosphere packaging. Bosch Packaging Technology; www.boschpackaging.com

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9001:2008

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Standard No. 10-04*

See Food Master, p. 52 © 2011 Donaldson Company, Inc. Minneapolis, MN. All rights reserved.

* PF-EG & PG-EG single filter element housings meet 3-A Sanitary Standards.

www.foodengineeringmag.com | Food Engineering | October 2011

61

TECHNOLOGY S O U R C E B O O K

TERMINAL BLOCKS Featuring dual jumper rows, WAGO TOPJOBS 2006 Series disconnect and fuse terminal blocks are suitable for industrial applications requiring disconnection, isolation and fuse protection of analog signals. They consist of push-in termination for ferruled or solid conductors, including WAGO pivoting disconnect and blade-style fuse models. The knife disconnect block has a 30A/600V UL rating and shares a profile with fuse and through terminal siblings. The touch-proof pivoting fuse holder secures fuses in a clip for correct insertion/ejection. The fuse plug carrier block eliminates contact with live components parts while changing fuses. WAGO Corporation; www.wago.com

October 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

Reliable Food Grade Synthetic Lubricants MOUNTING SYSTEMS Free of sharp corners and crevices, STRONGARM series RoundTop mounting systems feature radiused enclosure tops and a profile designed to accommodate a STRONGARM display with a Thin Client or KVM. Displays for the series are available in 15.1-, 17.1- and 19.1-in. sizes, as well as 19- and 22-in. widescreen models. The RoundTop MiniStation has an arm that features a circular cross-section and provides 340º of horizontal swivel on both the mounting and display ends; it is available in a variety of standard arm lengths, as well as custom lengths for specialized applications, and can be mounted on a wall, machine, work surface or post. STRONGARM Designs, Inc.; www.strongarm.com

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www.foodengineeringmag.com | Food Engineering | October 2011

800.749.5823 www.klsummit.com

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02/'2!-sSave the Date — Register by Dec 31 and Save $400! FOOD AUTOMATION & MANUFACTURING CONFERENCE AND EXPO is the industry’s only event presenting real-world solutions on automation, processing and packaging innovation, sustainability and food safety topics for Operations, Engineering and Manufacturing Executives. Join us in 2012!

W Sunday, April 22

10:00 – 10:30 a.m.

Refreshment Break

12:30 p.m.

Golf Tournament 3:00 – 5:30 p.m.

Registration 7:00 – 8:30 p.m.

Welcome Reception

W Monday, April 23 7:00 a.m. – 3:30 p.m.

Registration 7:00 – 8:00 a.m.

Continental Breakfast

10:30 – 11:15 a.m

Engineering Keynote: Manufacturing Innovation for Today’s Leaders Dave Haft, Senior Vice President, Sustainability, Productivity and Quality, Frito-Lay Fundamental change is occurring in how food is processed and raw materials are handled as food safety requirements become more stringent. This speaker will discuss how engineering and operations professionals can deliver manufacturing innovation and OEE while controlling capital equipment expenditures. 11:15 a.m. – 12:00 p.m.

Creating a No-Compromise Operations & Manufacturing Culture Neil Ducoff, Founder and CEO, Strategies

When compromise seeps in, it hinders growth, momentum and energy. Allow it to go unchecked, and even very achievable goals can turn into pipe dreams. This speaker will show you how to turn missed opportunities into manufacturing home-runs. No-compromise leadership is a commitment to a higher standard that guides a business culture to extraordinary achievement.

8:00 – 8:10 a.m.

Welcome Patrick Young, Publisher, Food Engineering 8:10 – 8:30 a.m.

Opening Remarks: The State of Food Manufacturing Joyce Fassl, Editor in Chief, Food Engineering

12:00 – 1:30 p.m.

Theme for Day One: Addressing Manufacturing’s Current Critical Challenges 8:30 – 9:15 a.m.

Lunch Buffet 12:00 – 3:30 p.m.

Expo

Keynote Address: The Age of Transparency Public and customer demand for greater transparency in food manufacturing is causing many processors to refocus their outlook regarding social responsibility as well food safety. This speaker will address how embracing transparency with science-based technology can lead to profitability. 9:15– 10:00 a.m.

Food Safety Modernization Act: What You Need to Know Now Kurt Deibel, Vice President, Quality & Food Safety, HJ Heinz New legislation and resulting enforcement often create questions concerning compliance. This presentation will address the latest trends in food safety management, effective track and trace systems as well as food safety compliance on a global basis.

1:00 to 4:00 p.m.

Solutions Theater 2:15 –2:45 p.m.

Refreshment Break Stations 5:00 – 6:00 p.m.

Expo Reception 6:00 – 8:00 p.m.

Harbour View Barbeque

W Tuesday, April 24

8:00 – 8:15 a.m.

Opening Remarks

7:30 a.m. – 1:00 p.m.

Registration 7:30 – 8:30 a.m.

Theme for Day Three: Sustainable Plant and Process Practices 8:15 – 9:00 a.m.

Breakfast 7:30 – 9:00 a.m.

Expo 9:00 – 10:00 a.m.

Solutions Theater 10:00 – 10:30 a.m.

Refreshment Break Theme for Day Two: Practical Measures for Improving Plant Performance 10:30 a.m. – 12:00 p.m.

Session A Packaging Technology 10:30 a.m. Robotics vs Continuous Motion Terrence Southern, Senior Engineer, Flexible Automation, Frito-Lay North America, Inc.

Social Responsibility: Addressing Customer and Consumer Concerns Speaker: Leigh Ann Johnston, CPEA, EHS Training, Communication, & Sustainability Manager, Tyson Foods, Inc. Demonstrating social responsibility is important in being an employer of choice, engaging company critics and effecting improvements in both food and worker safety. Maintaining business-to-business relationships is also a prime motivation. Hear how a leading processor embraces this crucial topic. 9:00 – 9:45 a.m.

Wastewater Treatment Paybacks and Benefits The cost and availability of fresh water is becoming an issue for some facilities, and many regulators are mandating organic load reductions. High levels of suspended and dissolved sugars, protein and fat pose a special challenge for food plants. This speaker will show how to achieve cost-effective wastewater treatment. 9:45 – 10:15

11:15 a.m. Best Practices in Machine Safety

Refreshment Break

Session B . . . . . . Plant & Process Controls

10:15 – 11:00 a.m.

10:30 a.m.. . . . . . .Overcoming the Challenges of Legacy Systems 11:15 a.m. . . . . . . .Best Practices in Automated CIP

Improving Your Plant’s Energy Efficiency

12:00 to 1:15 p.m.

Networking Luncheon 1:15 to 2:30 p.m

Ask the Experts Panel: Perfecting Your Continuous Improvement Plan This special session featuring a panel of food and beverage industry experts will present different viewpoints on various continuous improvement methods such as lean manufacturing, Six Sigma, OEE, KPIs, Kaizen and high performance work teams. These experts will address your top manufacturing challenges. 2:30 to 3:00 p.m

Refreshment Break

Energy efficiency and its relation to a product’s carbon footprint are becoming priority concerns for leading food companies. This presentation will cover topics such as energy-efficient lighting, greenhouse gas emissions reduction, boiler optimization and other plant and equipment controls to reduce energy usage. 11:00 – 11:45 a.m.

Bleeding-Edge Energy Technologies: Assessing the ROI Producing energy from plant waste is an actuality at some food and beverage manufacturing plants. Learn how one innovative food processor is using bio-digester technology to boost its bottom line. 11:45 a.m.

Closing Remarks 12:00 noon

Conference Adjourns

3:00 to 3:45 p.m.

Plant Security Audits: Protecting Your People and Assets The ability to document access-card use, the condition of perimeter defenses and other aspects of safeguards against intentional food contamination will likely be requirements of the Food Safety Modernization Act. Learn how to upgrade your security systems in a cost-effective manner.

WHY GO ALONE? Learn more when you bring your colleagues and share ideas. Save with the Team Discount!

3:45 to 4:30 p.m.

Plant of the Year Award Join us as we honor the 2012 Food Engineering Plant of the Year Award Winner. Each year, only one food or beverage plant in North America earns this award. 4:30 to 6:00 p.m.

Plant of the Year Reception

W Wednesday, April 25 7:00 – 8:00 a.m.

Register by December 31 and

SAVE $400! Developed and Produced by:

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QUESTIONS? Contact Marge Whalen, Senior Event Manager at 847-405-4071 or [email protected]

State of Food Manufacturing Processors Trim Spending

Staff expansions and production efficiencies are bright spots in an industry feeling the effects of economic forces beyond its control.

` Kevin T. Higgins, Senior Editor

C

onsumable products people must have—food, beverages, medication—are deemed recession proof. A double-dip recession, on the other hand, can trigger unanticipated belt tightening. The impact of macro-trends can be seen in the new product formulations and anticipated capital expenditures of food companies. Participants in this year’s State of Food Manufacturing survey indicate spending will be flat this year for production, packaging and process-control equipment, and a small downturn in budgets for automation hardware and software is likely—and that was two months before political brinkmanship took the federal government to the edge of default. “People have to have a job to buy things,” one survey respondent correctly observes, and the expectation is increasing that they will use the available dollars to buy healthier, less indulgent foods. The dip in spending for process control systems comes at a time when the need for more automation is great. “Automation to reduce headcount and adjust for production” is the top trend impacting food manufacturing, one reader writes, and a chorus of “Amens” can be heard between the lines in many other respondents’ comments. Whether for better inventory management, improved cost control or some other purpose, food and beverage professionals say there are 1) Greater automation implementation gaps in their automated control systems that need to be filled. Funding the investments, on 2) Raw material costs the other hand, may be problematic. 3) Greater product diversity Despite the challenges and constraints, 4) Greener manufacturing practices throughput is expected to increase, albeit at a 5) Focus on Lean/Six Sigma slower pace than recent years. Food Engineering readers expect company-wide throughput to go 6) Macro-economic issues up an average of 4.7 percent this year, less than 7) Better operator & maintenance training half the growth anticipated in 2009 and 2010. 8) Improved energy management The outlook for respondents’ own facilities is 9) Demand for healthier products marginally better (see chart on page 70). Production still is booming at many facilities, 10) Wireless technologies with slightly more than half anticipating an aver*Based on their impact over the next five years, age throughput increase of 16 percent at their as identified by readers. plants and 14 percent company-wide. But less Source: Food Engineering’s 2011 State of Food production is in the cards at one in six facilities, Manufacturing Survey. and at one-third of that group, reductions of 20 percent or more are expected. Poor business

Top Trends Impacting Food Manufacturing*

www.foodengineeringmag.com | Food Engineering | October 2011

67

STATE OF FOOD MANUFACTURING

Tighter belts for equipment purchases average increase 2004

6.2%

2005

3.8%

2006

4.8%

2007

7.5%

2008

5.4%

2009

0.98%

2010

4.6%

2011

0.3%

8-year average:

4.2%

Source: Food Engineering’s State of Food Manufacturing Survey, 2004-2011.

Budget constraints hit automation and controls average increase 2004

5.3%

2005

no change

2006

4.5%

2007

9.5%

2008

5.8%

2009

1.5%

2010

3.6%

2011

(0.3%)

8-year average:

3.8%

of the improvements. Past performance plays a part in the prognosis of others: “Because we have increased every year in the last 10 years,” is one respondent’s analysis. Another comment underscores the competitive nature of manufacturing, even when it’s friendly competition from a plant with the same ownership. “Business is better this year, but more of the work is being transferred to our larger, newer facility,” a reader writes. Investing in people and plants Plant improvement activities and staffing levels remained positive in the last year, although activities on both fronts were less pronounced than the previous year. One in three respondents reports the addition of a new line at their firms in the past 12 months, a solid sign of manufacturing investment but the lowest ratio in eight years. Movement away from outsourced production continued, with fewer than one in 10 saying more work is being outsourced. Outsourcing peaked in the 2006 survey, when almost three in 10 indicated more work was being done by copackers. Reflecting on a positive outlook, one food professional points to his company’s decision to “invest capital into a manufacturing line” that will allow it to “repatriate a product line back to our plant.” More firms are boosting their manufacturing and engineering staffs than cutting them, although the positive margins have narrowed (see chart on page 72). On the other hand, staffing additions are close to the 10-year average for both manufacturing and engineering. Negative employment trends were

Process control technology purchases

Source: Food Engineering’s State of Food Manufacturing Survey, 2004-2011.

conditions are the fallback for factories in decline. One reader suggests “consumer purchasing changes due to the economy” and higher price points caused by rising raw material costs are aggravating those changes. “Expendable products in a poor economy” is another reader’s epitaph for his firm’s fortunes. For those experiencing increased production, various explanations are offered. Popular new products, equipment upgrades and price reductions made possible by process efficiencies explain some 68

October 2011 | Food Engineering | www.foodengineeringmag.com

Percent planning to buy Lab analysis equipment/software

31%

Digital sensors/transmitters

30%

Motion/motor controllers

28%

PLCs

28%

Wireless plant networking equipment 24% Source: Food Engineering’s 2011 State of Food Manufacturing Survey.

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STATE OF FOOD MANUFACTURING

Scaled back production expectations Anticipated throughput gains 2009

2010

2011

At respondent’s plant

11.2%

11.5%

4.9%

At respondent’s company

11.4%

11.5%

4.7%

Source: Food Engineering’s State of Food Manufacturing Survey, 2009-2011.

reported in the 2008 and 2009 surveys, reflecting downsizing that occurred in 2007 and 2008, when the economy crashed. The point of automation is to reduce headcount, of course, making organic growth essential for employment growth. Greater product diversity and increased changeovers on existing lines make throughput improvement more challenging, and four out of five readers rank equipment upgrades as their top priority for improving productivity. Opera-

Brick & mortar projects still struggling 800

Total Projects* Expansions/Renovations New Plants

Number of projects

700 600 500 400 300 200 100 2001

2002

2003

2004

2005

2006

2007

2008

2009

*Based on projects valued at $1 million or more Source: Food Engineering’s Food Plant Construction Survey.

70

October 2011 | Food Engineering | www.foodengineeringmag.com

2010 14-year average

tor skill training is the second priority, with threefourths of respondents saying there is a great need or some need for improvement in that area. Better maintenance systems ranks third, with one in five seeing great need for improvement. Most organizations can benefit from closer communication between departments and job functions, and the need for a dialogue between marketing and production is glaring. Respondents rank improvements in that area as their fourth highest priority, up sharply from a year ago, when it ranked twelfth. Controls upgrades also moved up in the pecking order, leaping to eighth from 17th out of 18 factors. Only 11 percent of readers believe there is a great need for better tracking of overall equipment effectiveness (OEE) if productivity is to improve, and almost half (46 percent) say there is no need for better OEE reporting. To be effective and timely, the OEE metric requires automated data capture and reporting, and fewer than half of survey respondents work at plants with that capability. At manufacturing sites with the necessary MES infrastructure, OEE averages 67 percent, meaning saleable goods are being produced two-thirds of the time that machinery is available for production. The average OEE improvement goal is 73 percent. Data systems aren’t a requirement for improved performance; four out of five readers indicate their organizations have implemented people-oriented continuous improvement efforts. Six Sigma programs are in place at a quarter of respondents’ plants. Two in five plants have implemented lean manufacturing or total quality management programs, closely followed by self-directed work teams (36 percent) and total productive maintenance programs (31 percent). As the ratios suggest, multiple initiatives are the rule. One respondent cites an “integrated company program which uses TPM as a part,” while another writes, “Consistent refinement and evolution of production/manufacturing techniques” is his organization’s approach to continuous improvement. Revised shopping lists The programmable logic controller (PLC) is an icon of food and beverage automation, and it topped the controls hardware and software shopping list throughout the last decade. But the PLC became mature technology years ago, and this year’s survey suggests it is on its way to obsolescence. Until 2010, the majority of survey respondents indicated PLCs were in their plant purchase plans, with 85 percent saying they would purchase them in 2004. The

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STATE OF FOOD MANUFACTURING

Positive staffing trends continue Percent of companies making changes in previous year

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added engineers

cut engineers

added mfg. staff

downsized mfg. staff

2002

9%

7.8%

18%

7.8%

2003

8%

8%

18%

15%

2004

11%

15%

19%

21%

2005

16%

13%

21%

21%

2006

19.1%

14.4%

27%

19.6%

2007

18%

10%

32%

12%

2008

10%

12%

19%

21%

2009

10%

14%

17%

21%

2010

23%

8%

25%

13%

2011

13%

9%

18%

15%

Source: Food Engineering’s State of Food Manufacturing Survey, 2002-2011.

numbers have been declining ever since, and this year, barely one quarter of readers plan to buy them, dropping the PLC to the third most frequently purchased process control technology. A similar slide is occurring with HMIs, which fell from third to ninth, appearing on the shopping lists of only one in five readers.

The new automation hardware king is lab analysis equipment, closely followed by digital sensors and transmitters. About three in 10 plants will add those items to inventory this year, a ratio consistent with previous years. Wireless plant networking equipment jumped to the No. 5 spot from 11th last year, with

In pursuit of GFSI standards Percent of respondents seeking third-party food safety certifications SQF Level 2

25%

SQF Level 3

7%

BRC

10%

FSSC 2000

3%

Global Red Meat Standard

2%

Synergy 22000

2%

Pursuing/not attained

13%

Not pursuing GFSI

38%

25% 38%

7%

10% 13% 3% 2%

2%

Source: Food Engineering’s 2011 State of Food Manufacturing Survey. See Food Master, p. 49 October 2011 | Food Engineering | www.foodengineeringmag.com

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STATE OF FOOD MANUFACTURING

Who answered the survey? Readers of Food Engineering provided the feedback that serves as the basis of this report. A total of 130 readers responded either to surveys mailed in late May or to an e-mail invitation to complete the questionnaire online. Almost a quarter (22 percent) of respondents’ job function involves engineering, with general administrators and managers accounting for almost a fifth (19 percent). Operations managers account for 14 percent, followed by R&D (13 percent), production management (10 percent) and quality control (8 percent). The rest were spread among purchasing, packaging and the other.

one in four readers including them on their acquisition lists. Wired networking equipment, by contrast, will only be purchased by one in 10, half the level of four years ago. Reader opinions of food safety initiatives were solicited, beginning with the Food Safety Modernization Act (FSMA) and its impact on manufacturing and business operations. Almost three in 10 indicate FSMA would not affect operations, while a third agrees with the statement, “We already practice what FSMA preaches, so it is not an issue.” One in

A wide variety of food and beverage companies are represented, with processors of meat, poultry and seafood products representing the largest category at 16 percent. Suppliers of flavors, ingredients and supplements constitute 14 percent of the sample, followed by baking and snack food producers (12 percent), beverage products (12 percent) and shelf-stable foods (7 percent). Plant head counts are smaller than last year, with more than four in five (82 percent) working at plants with 500 or fewer employees, compared to 57 percent last year. The average number of employees is 329.

four indicates they have created a checklist of changes needed to comply, and almost as many say the legislation will nudge their organizations toward electronic recordkeeping. One in 10 agrees with the statement, “FSMA could help stop another melamine crisis,” a reference to the chemical covertly added by Chinese processors to pet food in 2007 and milk and infant formula in 2008. Another 13 percent of survey participants agree with the statement, “FSMA will create an undue burden,” and oth-

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413

See Food Master, p. 84

74

October 2011 | Food Engineering | www.foodengineeringmag.com

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STATE OF FOOD MANUFACTURING

ers offer written comments, including one deriding FSMA as an “imposed change.” Referring to one of the audit standards approved by the Global Food Safety Initiative (GFSI), a reader reflects, “The switch to BRC was partially due to this act. Some provisions

are good, some may not help, but all of them will cost extra money.” Food and beverage manufacturers can choose from several GFSIendorsed standards when undergoing an independent third-party audit. The Safe Quality Food standard adminis-

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76

October 2011 | Food Engineering | www.foodengineeringmag.com

tered by the Food Marketing Institute is the preference of a third of manufacturing professionals, with 25 percent opting for SQF Level 2 and another 7 percent pursuing the more stringent SQF Level 3. The BRC standard developed by the British Retail Consortium is the choice of one in 10, with FSSC 2000, the Global Red Meat Standard and Synergy 22000 also garnering interest. One in eight (13 percent) of readers indicates they are in the process of acquiring GFSI certification, while two in five have not investigated any of the certification options. All the GFSI programs require evidence of a food safety management system, and FSMA extends the HACCP requirement to all food and beverage processors. But only three out of five readers say their companies have established a food safety management system, the same ratio of those with capabilities for lot-level traceability. Federal regulators waited 15 years to extend HACCP beyond meat and poultry plants, but retail and foodservice customers have made HACCP a condition of doing business for years. Consequently, 77 percent of survey respondents indicate their firms have already implemented HACCP, including 46 percent with paper-based programs and 31 percent with electronic systems. Electronic signatures to verify HACCP compliance are in place at 15 percent of the plants. Participants in this year’s survey represent smaller operations than previous years’ samples, which may explain a drop in the number who have adopted corporate social responsibility or sustainability programs. Still, two-thirds have a program in place, with workplace safety and workforce diversity programs the most prevalent. A third of the companies know their water and energy inputs per unit of production, and a quarter can calculate their carbon footprint. Participation in the Global Reporting Initiative and recycling programs also were cited. ❖

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LEGACY SYSTEMS

Weighing the costs, benefits and risks of a Replacement System Most replacement systems will, or at least should, provide marginal benefits over your legacy system. ` Olin Thompson, Contributing Editor

A

ccording to an online definition, “A legacy system is an old method, technology, computer system or application program that continues to be used, typically because it still functions for the users’ needs, even though newer technology or more efficient methods of performing a task are now available.” But for food and beverage processors, another more realistic definition applies: It’s a system that works. It may be old and creaky, but nontechnical executives typically view it as “tried and true.”

Replace, renovate or add-on Too often, if you have a legacy system, the only option that comes to mind is to replace what you have. However, other options exist, including doing nothing, doing some renovation or adding on functions. Whenever you consider a replacement, you must compare your reasons to the realities of this decision. Those realities include cost, disruption and risk. You have to pay the cost of buying and installing the replacement system. Plus, you have to face the risk of disruption and a typical dip in opera-

www.foodengineeringmag.com | Food Engineering | October 2011

79

LEGACY SYSTEMS tional efficiency and effectiveness before, during and after the implementation. Will the new system really be better by an amount that justifies the cost, disruption and risk? If you decide to replace your existing system and then add on functions to improve your business (see story

below), remember the time involved in implementing the replacement system means the ROI from the added function is delayed. (You could try to implement both the replacement system and new components at the same time, but are you willing to accept the risk and even greater disruption in doing so?)

Executing the replace option Peet’s Coffee & Tea of Emeryville, CA serves multiple customer channels with fresh roasted specialty coffees and teas. These channels include 200 retail locations, direct to consumer, nearly 9,000 grocery stores plus a large number of foodservice operators. During the past five years, the San Francisco Bay area company has doubled its revenue and today enjoys $300 million in sales. The company is proud of its competitive distinctions of roast-to-order and delivering the freshest products possible. It does not keep an inventory of ready-to-ship roasted coffee. Each day starting at 3:00 a.m., Peet’s performs the roasting for the orders that arrived from all channels through midnight of the previous day for delivery within 24 to 48 hours of the order submission. What was wrong with Peet’s legacy systems? Shawn Conway, chief supply chain officer at Peet’s Coffee & Tea, explains: • The system could not handle transaction volumes during peak periods, resulting in a negative impact on customer service. • Different on-entry systems for each channel made consolidating orders for production a slow, error-prone and laborious task each day. • Some elements on homegrown systems crashed, interrupting operations. • Financial inventory was only updated once per month. • The technology environment was complex and challenging to maintain. • IT had an enormous workload keeping multiple custom-written, unconnected systems up and running and integrated. • Business managers had reservations about the accuracy of the information. Peet’s decided it could not continue to maintain both excellent quality and fast growth without making a change in its business management technology, simplifying its IT administration and giving business decision-makers reliable, current information. It also wanted to streamline reporting and compliance with Securities Exchange Commission and FDA regulations. “We wanted a single system that would let us reliably manage the quality goals we set, run as efficient an opera-

80

October 2011 | Food Engineering | www.foodengineeringmag.com

tion as possible and sustain the company’s momentum,” Conway explains. To plan the software implementation for the most impact and meet the requirements of different business groups within the company, Peet’s began with a thorough, twomonth discovery project. It noted everything it hoped to accomplish, took a detailed inventory of existing software and developed functional and technical requirements. Peet’s created a request-for-proposal document and invited responses from technology vendors. It selected Microsoft Dynamics AX offered by Junction Solutions, a Microsoft Gold Certified Partner with expertise in and product offerings for both food manufacturing and multichannel retail. Peet’s implementation spanned 18 months with the deployment of a single instance of Microsoft Dynamics AX together with the Junction Solutions software at the company’s business and production locations. Initially, finance, business administration, order management and other lines of business received the solution’s functionality. In the second phase, the solution was extended to production. Peet’s now enjoys a business management solution that supports the company’s quality standards and enables it to keep growing. According to Conway, “Peet’s Coffee & Tea succeeds by combining artisan skills and technological enablement. We did not automate anything that humans could do better, but Microsoft Dynamics AX and Junction Solutions’ technology help make sure our people and our products are at their best every day.”

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LEGACY SYSTEMS

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October 2011 | Food Engineering | www.foodengineeringmag.com

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may mean an integrated vendor is not up to the challenge. A renovation means you stay with the same vendor and product and reinstall or update to the most current release. Like any business decision, pluses and minuses exist. Not having to pay for new software is a plus; however, a vendor will often demand some money to allow you to get the newest release. The implementation will be simpler than the first time or with a new vendor or product. For example, users know the basic system and will only have to be trained on the changes; many of the required decisions have been made, so data conversion may not be an issue or be a minimum challenge. Of course, you should rethink business processes and data issues, but most of the decisions, training and data will still be valid. As part of a renovation, consider new functionality added to the existing system in later releases or from newer modules. For many of these functions, much of the groundwork has already been done, and implementation will be less burdensome. For some companies, the motivation for renovating a system is to eliminate existing modifications and the limitations and expense associated with them. Often, the requirements that originally drove your modifications have been addressed in the current release. But if modifications are still required, they will have to be addressed. What are the minuses of a renovation? You still have the old system, but you get some upgrades. However, some of your needs may not be fulfilled via the renovation route because the vendor never addressed certain issues.A very realistic issue is user acceptance. If the old system currently gets the blame for business problems or affects morale, your organization may not accept any solution that carries the old name. If you add the functions you require to the existing system, you can proceed directly to implementing the functions that will deliver ROI. That project will have to consider integration of the new

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torically, the best-of-breed option has had better function, and the single vendor option has had better integration. However, both these observations are questionable in today’s market. The major advantage of going with your existing supplier is that the new

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quickdraft.com See Food Master, p. 90

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software should work with the old software. Although you will normally be forced to upgrade the existing system to the current release, the new function’s information and business process should be integrated, supported and maintained by your existing supplier. The reality is that the existing vendor should have better integration and will bear the cost of maintaining that integration. This is important since integration is a major cost when using the best-ofbreed option. The selection of an add-on product must include the ability of the product to integrate with the existing systems. Was it built to be integrated? What integration technology does it support? What are the cost and risk of maintaining the integration? How long will the integration take? Part of the integration trade-off has to do with the quality of the integration. Therefore, the question for the best-of-breed option is, “Can these products be integrated in a practical way?” Practical does not mean best; it means acceptable given all the other trade-offs that have to be made. You will have to live with integration code that will need maintenance and duplicate files that may get out of sync, the finger pointing between the two vendors when one or both of the two systems are not working correctly and two new release cycles that will prove to be always perfectly out of sync. In general terms, applications that take data from systems and never put any information back, like business intelligence, are the easiest integrations. Putting back highly formatted data, like a forecasting application, is more difficult. The most challenging integrations are those that interactively work with more complex systems, like warehouse management. An example of a company serving the food industry that has done both renovations and additions is Emerald Performance Materials. The company produces and markets additives for a broad range of food, personal care and industrial applications, enabling these products to last longer, look, smell, taste

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or perform better. Product lines for food and beverage applications include preservatives, colors, foam control and other ingredients. Emerald’s IT strategy includes a core ERP system called PRISM from Infor. According to Jerry Oberdove,

Emerald’s director of IT services, “The PRISM system meets our needs; it is proven to be rock solid and stable. It provides our operational systems like purchasing, customer orders, production, inventory and distribution. It also does an excellent job of costing.

Booth #1627

“When we looked at alternatives, we did not find a replacement system that gives Emerald the marginal business improvements needed to justify the cost, disruption and risk of changing systems. In addition, we felt the approach we took could maximize the benefits from our legacy system and allow our businesses and staff to focus on key strategic growth objectives critical to generating greater value for the company.” Emerald has surrounded PRISM with JD Edwards financial applications available from Oracle and a number of best-of-breed systems including Business Intelligence, Document Creation, MSDS and Pricing Analytics to identify “price leaks.” For support, Oberdove says they have been relying on a third party, Precision Solutions Group, Inc. or PSGI. “PSGI is an integral part of our total solution. They support PRISM and the JD Edwards plus do related projects. Yes, they know PRISM, but they also know the food industry and the Emerald business.” Should your legacy system be replaced? The first question is, “Does it serve your needs?” If the answer is yes, then justifying a replacement would be difficult. Often, people talk about why a new system would be better, so the right question to ask is, “What’s wrong with our existing system?” Most replacement systems will, or at least should, provide marginal benefits over your legacy system. Consequently, another fundamental question should be, “Do the marginal benefits outweigh the cost, disruption and risk of implementing a new system?” If the answer is no, consider renovating or adding on to what you have. ❖ For more information: Kate Mayer; Junction Solutions; [email protected] Microsoft Dynamics; [email protected] Dave Kravitt; Precision Solutions Group Inc.; [email protected] Andrew Kinder; Infor; [email protected] Doug Chapman; Oracle; [email protected]

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FLEXIBLE MANUFACTURING `Suction end-effectors gently pick up ice cream bars for placement in an open-front carton. Thanks to dramatically lower costs for vision-guided robotics, flexible automation solutions are proliferating in secondary packaging. Source: Blueprint Automation.

The automation conundrum Flexibility is an increasingly important attribute, but manufacturing professionals must strike a balance between the need for high-speed automation and production adaptability. ` Kevin T. Higgins, Senior Editor

T

he latest in engineering innovation and automation was on display in 1984 when PepsiCo Inc.’s Frito-Lay division opened its Casa Grande, AZ snack food plant. The project was sufficiently impressive to warrant designation as Food Engineering’s 1985 Plant of the Year. Among the facility’s leading-edge technologies at the time was an automatic storage and retrieval system (AS/RS), complete with automatic guided vehicles to ferry full pallets to the AS/RS. The AGVs long since have been replaced by lift trucks, but the AS/RS continues to serve the high-volume plant’s warehousing needs.

Fast forward a quarter of a century to Avon, NY, where Barilla America operates Food Engineering’s 2008 Plant of the Year. Servo-driven case packers and other automation advances are reflected at Avon, but AS/RS was not even considered. The days of shipping full pallets already had ended, and Barilla engineers designed a warehouse work cell with minimal automation and many human hands to generate the shrinkwrapped multi-packs for club stores and mixed pallets that large retailers are demanding. In Casa Grande, that kind of customization isn’t possible, and full pallets must be sent to another site to fulfill those orders.

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FLEXIBLE MANUFACTURING Absent the gift of clairvoyance, engineers can’t design machines and systems to meet needs far into the future. Even when change is anticipated, technical limitations may put a solution out of reach. Consequently, manufacturing adaptability requires a cautious approach to automation. Consistency and throughput rates require high-speed equipment, but shifting customer requests and changing package sizes and product lineups are yellow caution flags on the automation racetrack. Flexibility carries a premium for copackers and contract manufacturers, and shorter contracts and smaller production runs have put the brakes on recent automation projects, suggests Mike Wagner, business manager of OEM packaging solutions at Milwaukee-based Rockwell Automation. “Before the recession, they had to automate to keep up with their orders, and the ROI on a machine was one order,” he says. In today’s environment, payback is harder to achieve, and the availability of skilled maintenance personnel forces some companies to do more hand-packing in secondary packaging than they would like. “Nobody’s going to invest for a oneyear contract,” agrees David Dixon, a senior director with Kansas City’s Burns & McDonnell. But the cost and availability of labor, coupled with broad adoption of advanced robotics in secondary packaging, is paving the way to more flexible automation, even in markets deemed automation averse. In China, contract manufacturers are investing

heavily in automation as rising wages make manual processes less attractive. Wagner cites Foxconn Technology Group, the world’s largest contract manufacturer of electronic components: The firm is investing in a 10-fold increase in robotic-motion machines and should have 300,000 cells in place next year. “You certainly have to think of machine design differently,” Wagner allows, “but robotics makes changeovers a very simple process, particularly for collators, stackers and casepackers in secondary packaging.” Meet Mr. Robot Packaging operations offer the greatest opportunity and most pressing need for flexibility. Yet the inability of continuous motion machinery to adapt has fostered an aversion to automation in many cases, particularly when future configurations of new products are in doubt. “Some of our clients have shunned automation in recent years, particularly with new products,” notes John Gunst, a packaging engineer in POWER Engineers Inc.’s Meridian, ID office. “When you have a hard system, you’re limited in the changes you can make.” Historically, designers like Gunst included open space between flow wrappers and casepackers to accommodate the additional machinery needed to build different multi-pack pairings, “but people won’t give you the 10 feet you will need anymore,” he frets.

Best of both worlds Add flexibility and waste reduction to the list of motivations for beverage processors to switch from batch to continuous manufacturing. Additional help in achieving these objectives is coming from the pharmaceutical industry, where batch processing and mass-flow metering are giving way to inline mixing and instantaneous adjustments from a feedback loop. Inline blending has been available for years, though convincing manufacturers to scrap their syrup room tanks and invest in continuous technology for soft drinks is a hard sell. But carbonated beverages are mature products, and today’s beverage growth comes from sports drinks, flavored waters and other noncarbonated thirst quenchers. As the complexity and raw material costs for these new-age beverages increase, manufacturers are taking notice of the path trod by biopharmaceutical companies and considering investments in continuous, inline mixing. A new supplier of such systems is SensiBlend, a suburban Chicago firm licensed to sell a liquid blending system

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outside of the pharmaceutical industry. The technology was developed by TechniKrom, a fabricator of chromatographybased filtration and purification systems. Early this year, SensiBlend began marketing the technology to beverage producers. Instead of simply metering in ingredients and relying on downstream quality-assurance testing, SensiBlend’s system relies on process analytical technology (PAT) to instantly analyze inputs from sensors measuring pH, UV and other variables to adjust ratios before releasing fluid flow, according to Kevin Henretta, chief engineer. “You program the system with a detailed chemical analysis of what constitutes a golden batch,” he explains, and PAT ensures these set points are met. “If you’re below set points, PAT speeds up the pump, but if it isn’t in compliance after a minute, it stops the pump,” Henretta adds. With more products straddling the line between foods and drugs, and the need for beverage companies to produce shorter runs of more product variations, Henretta and his colleagues see new opportunities for continuous blending.

FLEXIBLE MANUFACTURING ended up with a more expensive machine with unused capabilities. Casepackers that can load French fries vertically for foodservice and horizontally for retail shipment have been BPA staples since the company’s inception, but integration of that machine with a case erector that’s “going to save you some real estate” in an 18-ft. by 5-ft. footprint enhances flexibility, according to John Rice, a mechanical engineer with Colonial Heights, VA-based BPA. Four servo axes do the work in the casepacker, with a similar number directing motion in the case erector module.

` While some lines have automatic case packing and palletizing systems, workers do much of the work at Shearer’s Foods’ Brewster, OH plant, where privatelabel and contract manufacturing account for a large portion of production.

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Some integrators have tried to resolve the issue with servo-driven collation belts, though that can complicate design, Gunst believes. A better solution is multiple scara or delta-style arms coupled with vision systems. The expiration of patents protecting 3- and 4-axis delta robots opened the floodgates of innovation, and suppliers “are selling flex pickers by the truckload,” he says. Gunst cites the example of a multi-function machine with a small footprint from Blueprint Automation (BPA) to illustrate his point. The case erector squares up and forms the cases, then feeds them to an articulated arm for vertical packing. “It’s simple engineering but a brilliant idea,” says Gunst. “There’s no issue with restacked boxes.” Multi-function machines can deliver unneeded flexibility. In response to German retailers, Barilla’s European operations commissioned a casepacker that could build a displayable case. The machine fabricates a cap that doubles as a display base for in-store merchandising. Unfortunately, the procedure for removing the case wrap and repositioning the cap was lost in translation to the people responsible for executing it. The machine also can output conventional cases, but Barilla

October 2011 | Food Engineering | www.foodengineeringmag.com

Machines on wheels Contract manufacturers feel the pressure to adapt with each new job. “We made the decision in the early 1980s to build in flexibility with every piece of equipment,” relates Rick Teeny, president of Portland, OR’s Teeny Foods Corp. “At that time, 90 percent of our production was branded products. Today, we are 98 percent private label.” More than 160 types of pizza dough, breadsticks, pita breads, presheeted dough and the firm’s signature “pocket bread” are manufactured at its newest plant, which opened in 2004. “Packaging equipment is almost entirely on wheels,” says Teeny, as is a substantial share of production machinery. As automation expanded over the company’s 47-year history, management resisted the temptation to lay off workers, opting instead to train them for higher-skilled jobs. The policy has paid off with a large, well-seasoned mechanical staff. When prospective clients have requested product requiring a new line, Teeny boasts his staff has rolled in the necessary components and ramped up to full production in as little as four weeks. “A copacker’s facility needs to provide a competitive advantage,” says Burns & McDonnell’s Dixon. “Instead of just saying, ‘Give me the specs for the product you want,’ sophisticated copackers are saying, ‘I will create added value with enhanced services.’” These might include assistance in packaging design; retail support in creating end-cap displays, pre-priced packages and coupon inserts; and preproduction development to ensure rapid scale-up and minimal waste. Hearthside Food Solutions LLC exemplifies the value-added approach. Founded in 2009, Downers Grove, IL-based Hearthside has stitched together a 12-plant network, seven in the purchase of Consolidated Biscuit Co. Three locations boast R&D centers that are “not so much R as D,” explains Brian McNamara, vice president of sales & marketing. Brand owners typically take a new product directly from their R&D lab to a contract manufacturer, and

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FLEXIBLE MANUFACTURING ` Mechanical application of base coats on ice cream was the first automation project at Celebration Foods, a conversion aimed at increasing efficiency without compromising flexibility. Source: Stanley Jesudowich.

scaling up for commercial production can be a time-consuming process. “We have to be fast and flexible to survive,” McNamara points out, and the R&D departments, along with a fabrication shop at a 1 million-sq.-ft. bakery in McComb, OH, enable Hearthside to shrink the time line for getting new products to market.

While Hearthside’s fab shop can build electrical boards and tool conveyors and other components, it is unable to fabricate advanced automation solutions. Oftentimes, these systems are only available through custom engineering, a prohibitively expensive solution that makes manual solutions the only option. That scenario plays out daily at Shearer’s Foods Inc., winner of this year’s Plant of the Year award (Food Engineering, April 2011). Shearer’s produces its own branded snack products but also does extensive work in private label. Both types of products are made at its Brewster, OH facility, where automated casepackers and robotic palletizers perform secondary packaging duties for the Shearer’s brand, while operators fill cases with different sized bags in varying patterns for retailers and other manufacturers. The work is tedious, and turnover is an issue. Happily, affordable technology is becoming commercially available. Last spring, BPA sold its first vision-equipped delta-style case packer with a PLC-controlled changeover function, enabling hands-free changeover. Designed specifically for potato chips and other fragile snacks, the compact unit (4 ft.

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FLEXIBLE MANUFACTURING ` Workers at Barilla America’s Avon, NY plant reassemble custom orders. Club packs, mixed pallets and other customized orders require a level of flexibility that machines can’t provide. Source: Jen Rynda.

wide, 8 ft. high) hovers over a conveyor and packs up to 130 small bags a minute. In fact, most manufacturers would gladly trade a modicum of flexibility for an automated solution at an affordable price. W hen New Britain, CT-based Celebration Foods LLC commenced operations in 2008, it was constrained by a $22 million budget for both construction and equipment (see Food Engineering’s April 2009 New Plant of the Year). Swarms of workers decorated its ice cream cakes, a process that management said produced a handcrafted look shoppers craved.

The remark rang of rationalization. In fact, within months of plant startup, the company began toying with a Unifiller machine on casters, wheeling it in and out of the line as engineers and mechanics experimented with “mechanically assisted” application of a base coat of icing over the ice cream. Capital constraints limited the opportunity for additional automation, but financing likely became less of an issue with Celebration’s acquisition early this year by Rich Products Corp. Manufacturers are not about to turn their backs on technology. As order volume builds, the need and financial justification for automation increase. The trick is implementing it in such a way that you can have your cake and retain flexibility, too. ❖ For more information: John Rice, Blueprint Automation, 804-520-5400, [email protected] David Dixon, Burns & McDonnell, 630-272-1677, [email protected] John Gunst, POWER Engineers Inc., 208-288-6100, [email protected] Mike Wagner, Rockwell Automation, 414-382-2000, [email protected] Kevin Henretta, SensiBlend, 847-556-9700, [email protected]

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T E C H U P DAT E : PU M PS Wayne Labs, Senior Technical Editor

` This SensiBlend skid features a bevy of PD pumps, sensors and controls and is able to process continuously inline and in real time. Source: SensiBlend.

Work smarter, save energy

`

The right pump used for the right application can make a significant difference in energy consumption.

O

bviously you can’t do without pumps in your plant—whether it’s to pressurize water for cleaning, to move it as an ingredient to a process, or to move a food product from point A to point B, where B might be a filling or packaging stage. But there are ways to think about pump systems that can improve process efficiency, save energy and potentially gain back some floor space as well. All this can be done without sacrificing the quality of food and beverage products that have to be pumped. However, getting the best results in handling product, moving CIP water/chemicals and saving energy requires input from as many sources as you

can get. These include pump suppliers, system integrators, consultants, skid builders and other processors—and events like FE’s Food Automation & Manufacturing Conference (FA&M). (For more on positive displacement pumps and CIP, See “Tech Update: Pumping Systems,” FE, April 2010.) Smart thinking applications While the US government has mandated the use of high-efficiency, three-phase motors (Energy Independence and Security Act of 2007) in the 1 to 500hp range beginning this year, the fractional improvement in efficiency gained with using premium-efficient motors won’t compensate for

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T E C H U P DAT E

` The TMFR series, and integrated pump-motor unit, features a motor with no moving parts. Instead, an internal magnet is driven through an electromagnetic field, and is capable of transmitting high torque to the pump shaft. Source: Fluid-o-Tech.

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the misapplication of pumps. “Many times we have seen installations that are using the wrong pump for the application or a pump that is sized wrong ‘just because we had it already,’” says Jim LeClair, global product manager for SPX Flow Technology. Providing the most efficient pump for the application isn’t always obvious. “Many times I see pumps that are put into applications that may not be the best selection,” says Sam Raimond, customer service supervisor at Fristam Pumps USA. “The most common issue I see is trying to fit a large 1750 rpm pump into an application thinking that a lowerspeed pump will be gentler on a customer’s product, when many times a more efficient, 3500 rpm pump would handle the product with less shear.” “Using a pump that is half as efficient can cost you more energy than purchasing a new pump even in a single-year payback scenario,” adds LeClair. “So, the real savings is from making sure the application of the pump within the process is correct.” These misapplications that LeClair describes could be the use of a rotary lobe pump in a centrifugal application, which creates a huge problem in pumping and energy efficiency—or the use of a very inefficient pump in a process application that would benefit from using a pump with a higher performance specification. For processors without years of experience, pump suppliers and system integrators have a wealth of knowledge about the proper application and sizing of pumps. Even though this knowledge exists, it is incumbent on processors to get the whole story from suppliers. “There is a glaring market failure to price in all the costs,” says Clyde Smith, Fluido-Tech technical manager. “In a perfect world, pumps would be chosen to minimize their total lifecycle costs.” Total lifecycle costs, says Smith, include the initial acquisition price, accumulated energy charges, maintenance costs and disposal/ recycling fees.

October 2011 | Food Engineering | www.foodengineeringmag.com

“When times get tough, there is a tendency for specifiers and end-users to fall into the trap of ‘cheapest is best’ without first considering the host of factors for reducing total cost of ownership,” says Chuck Treutel, Watson-Marlow MasoSine national sales manager. This is especially true for positive displacement pumps, which can be very application specific. Besides normal maintenance, ease of cleaning—whether manual or CIP—is also a major factor in a pump’s overall lifecycle cost. The longer cleaning takes, the longer the line is down. Pumps that are CIP-able should be engineered with ease of maintenance in mind, says Raimond. For example, Fristam’s FPR centrifugal pumps have front pull-out seals that eliminate the need to remove the pump head during seal change-out, he adds. Saving electrical energy Optimizing centrifugal pumps for a reverse osmosis (RO) filtration process improved efficiency for a Western US cheese producer; a single pump replacement consumed 15 percent less power than its predecessor. Alfa Laval worked with the processor to determine a suitable replacement pump, and suggested recording all the pertinent power consumption data for one week for one of the existing pumps in its multi-pump RO application. On a trial basis, the cheese processor installed a Model LKH-PF60 high-pressure centrifugal pump operating at the same duty conditions and recorded all the power consumption data for one week. The resulting information confirmed the LKHPF60 consumed nearly 15 percent less power than the existing pump, providing an $1800-perpump-per-year savings on electricity. Considering 2011 energy costs at the processor’s location of 4.5 cents per kilowatt-hour, savings in other parts of the country could be considerably larger, says Chad Hawkins, Alfa Laval sanitary pumps business development manager.

T E C H U P DAT E for the purpose of efficiency isn’t necessary. In fact, says Smith, good load matching can be difficult and sometimes impossible to do.

` These progressive cavity pumps move yogurt without damaging the product. Source: seepex.

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As a result of the successful trial, additional LKH pumps were purchased. Fewer were required to do the same work, reducing costs and increasing available floor space. In this RO application, LKH pumps can handle throughputs up to 1,200gpm with inlet pressures up to 600psi. In a series configuration, the pumps are daisy-chained inlet-to-outlet, and pressures are controlled by using VFDs and pressure transmitters on each pump, rather than running the pumps at full speed and using valves to control the pressure, says Hawkins. According to Darryl Wernimont, POWER Engineers market specialist, using VFDs with pumps saves energy, considerably reduces wear and tear on the pump and completely eliminates the throttling valve. VFDs also present a power factor of 1.0 to the electric utility system—even with less-thanoptimal pumps. This is good for two reasons. First, power companies like to see proper loading of their circuits. And second, when a plant’s power factor is off (highly inductive or capacitive reactance) from 1.0, the processor may have to invest in power factor correction equipment and/or pay the utility additional charges. The use of VFDs with brushless DC motors for speed control also saves energy costs, says Smith. Brushless DC motors consume electricity more or less in proportion to their pump load. Therefore, exactly matching the motor to the pump load

October 2011 | Food Engineering | www.foodengineeringmag.com

Compressed air savings Without a doubt , compressed air usage is one of the biggest utility expenditures for any plant. The problem is, according to seepex President Mike Dillon, maintenance and process engineers don’t often think to look at the cost of compressed air because it simply gets lost in the overall electric bill— unless someone connects a monitor to the compressors. A cco rd i ng to t h e US Department of Energ y ’s “Energy Tips—Compressed Air” Tip Sheet #2 (August 2004), a “potentially inappropriate use” for air as an energy source is in the powering of air-operated diaphragm pumps. It suggests solutions such as using proper regulators, adding speed control and/ or migrating to an electric pump instead. Energy consumption wasn’t the only reason Pukka Pies, located in Syston, Leicestershire, UK decided to replace its pneumatically operated air pumps with MasoSine SPS 2.5 pumps to transfer meat fillings. Noise levels and long cycle times were two other factors in making the change. “We were using a pneumatic air pump to transfer pre-cooked meat from a 200-liter-capacity, lowlevel hopper to a top hopper ready for the depositor to fill the pies,” says Simon Kemp, maintenance manager. “In the first instance, the pump was very noisy, and we wanted to improve the working conditions for our bakery operatives. We also found that the meat mixture—which is rich, thick and full of meat chunks and, therefore, must not be damaged—was problematic for the pumps we had on site,” he adds. “We needed to find a pump that could suction-lift the mixture from the mixing bowl up to the depositor feed hopper while maintaining product integrity.” The pie manufacturer asked for information on Watson-Marlow’s MasoSine positive-displacement (PD) pumps, and was introduced to the SPS 2.5 model, a pump suited to high-pressure, hygienic

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T E C H U P DAT E

` The OptiLobe pump has cut maintenance at Parmalat’s Collecchio dairy plant where it replaced an existing progressive cavity pump. Source: Alfa Laval.

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operations in food plants. The pump’s sinusoidal rotor produces powerful suction with low shear, low pulsation and gentle handling. “With the installation of the first MasoSine SPS 2.5, we managed to lower noise from 94 dB peak to 74 dB peak,” says Kemp. (In terms of human sound perception, a 10 dB decrease sounds half as loud as the original; a 20 dB decrease sounds one-fourth as loud as the original level.) The process of transferring meat to the top level depositor feed hopper is controlled by the processor’s own VFD system. In combination with the easily integrated SPS series pump, which has plenty of lift for the dense pie fillings, the new system is delivering a further benefit of 20 percent faster pumping times. “Furthermore, since the installation of the first MasoSine pump around two years ago, we now use far less compressed air—to the tune of 660 l (23 cu. ft.) per minute,” says Kemp. “This obviously equates to significant savings in our energy consumption.” Kemp also reports the pumps are easy to dismantle

October 2011 | Food Engineering | www.foodengineeringmag.com

and clean. “It only takes around 20 minutes before we are ready to go again, which is quicker than using our previous air pumps.” Diaphragm pumps, which can be used in product unloading or filler feed applications, do use compressed air, and while air operation provides a great deal of flexibility, this style pump has the reputation of being a high-energy user, says Wallace Wittkoff, hygienic director, PSG-Wilden/Mouvex. “A key reason for traditionally high energy usage is not from what most people might think: that the pump concept is inefficient. The primary reason is that the pumps are operated in an inefficient way because of their design,” he says. One solution to this problem that Wilden introduced some time ago—and is still in use today— can be found in its PX diaphragm air motor system. This system, according to Wittkoff, does for diaphragm pumps what trimming impellers or using VFDs has done for centrifugal pumps. The system makes sure the air volume (which correlates to energy) that goes through the pump matches the displacement of the diaphragm, which equals the displacement of the product pumped. Without this system, much more air goes through the pump and out the muffler than is actually needed. Nevertheless, eliminating an untuned, air-operated PD pump altogether and using an electrically powered PD pump can pay for itself pretty quickly, says Dillon. Depending on the application, Dillon has seen ROIs typically shorter than a year and, in some cases, a couple of months. The process of converting electrical energy to compressed air, and then using air to create mechanical energy to run a pump, is inefficient. Energy savings slipping away? In PD applications, rotary pumping systems with eccentric disc technology often represent a good choice for viscous liquids, but according to Wittkoff, these pumps can have their share of slippage when pumping water-like liquids with a viscosity of 1 centipoise (cps). “Positive displacement pumps by definition should have little slip, but the reality is that with low-viscosity products [pumped] against pressures greater than 100psi, slip can be more than 80 percent.” A typical lobe pump handling a water-like substance would nominally have a flow of 40gpm against 100psi pressure, but would actually pump only at 5gpm. The 35gpm difference is what “slips” and represents 88 percent of the amount of energy expended in unnecessary pumping. As the pump further wears, its slip approaches 100 percent, indicating time for a rebuild.

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T E C H U P DAT E ` Banks of centrifugal pumps operate a reverse osmosis filtration system at a Western US cheese producer. Alfa Laval LKH-PF60 pumps reduced energy usage by nearly 15 percent. Source: Alfa Laval.

According to Wittkoff, slip can be minimized by designing the pump to be “self-adjusting,” so the pump maintains its clearances as it ages, and slip can be held constant throughout

the useful life of the pump. Mouvex engineers have been able to create a pump (under conditions of a 1cps product pumped against 100psi pressure) whose slip at a flow of 40gpm can be held to 4gpm. This represents a 10 percent loss, which remains constant after several million cycles as the pump automatically adjusts clearances as it ages. Higher-viscosity liquids will have less slip through the pump. Progressive cavity pumps and lobe pumps have similar wear issues, according to Dillon. seepex’s Model SST/ SCT pumps all have adjustable stators. This means the compression between the rotor and stator can be set for the individual application. The most commonly touted advantage of the adjustable stator is that it lasts longer than conventional, molded-to-metal designs. The real benefit, however, is that only enough compression (also torque) needs to be added to overcome the differential pressure of the application, says Dillon. Molded-to-metal stators and lobe pumps typically come with a set or standard amount of compression, so the torque required is always in excess of what is required for the application. “As the compression decreases through erosion and

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October 2011 | Food Engineering | www.foodengineeringmag.com

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T E C H U P DAT E ` MasoSine MR and SPS series PD pumps are being used at Kinnerton’s UK confectionery plant. They replace older gear pumps that damaged product. Source: Watson-Marlow.

natural wear, the pump’s mechanical efficiency improves, but then once it wears too much, the volumetric efficiency starts to erode,” says Dillon. Model SST pumps provide an adjustable stator (smart stator technology) that allows the peak overall best efficiency to be maintained over the entire lifetime of the pump, adds Dillon. The user can minimize the depression and determine the best efficiency point, maximizing both mechanical efficiency and volumetric efficiency. Selection depends on the application Progressive cavity pumps can improve efficiencies in applications where existing pumps fail to deliver at very low temperatures. For example, Bulmers was experiencing problems at its cider plant when an existing pump had problems offloading a tanker truck of cider concentrate due to pressure in the pipe work. The pump took four hours to unload the tanker, and it also created unnecessary waste as it couldn’t completely empty the tanker. To provide a solution, a Mono Helios progressive cavity pump was installed at the plant to offload the concentrated apple juice used to make cider. The self-priming pump has a capacity of 3170g/hr. (12 cu.-m/hr.) at a pressure of 137psi (9.5 bar), and handles high viscosi-

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October 2011 | Food Engineering | www.foodengineeringmag.com

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T E C H U P DAT E

ties and solids in suspension. The flow is unaffected by system pressure changes. “The Helios pump has more than met our performance criteria and is able to offload the tanker in less than two hours, avoiding any demurrage charges,” says John Williams, cider production manager. “It handles the cold, high-viscosity

apple juice very well and is quiet in operation with very little vibration.” W hile a progressive cavity pump solved Bulmers’ tanker unloading problem, this type of pump was not the best solution for Parmalat SpA, a dair y in Parma, Italy. The dair y was looking for a solution to pump

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October 2011 | Food Engineering | www.foodengineeringmag.com

a milk product containing Omega 3, milk powder and chocolate milk. The pump had to run 12 hours a day and meet EHEDG/3-A/FDA regulations. The dairy was looking for a pump that would have a lower total cost of ownership in terms of maintenance. The dairy chose Alfa Laval’s OptiLobe rotary lobe pump. After 16 months of operation, the pump required no spare parts replacement, which lowered maintenance costs compared to the older pump. “The OptiLobe pump is very compact and easy to operate,” says Gianpaolo Saccani, Parmalat’s chief maintenance engineer who is responsible for all the company’s plants that prepare raw materials for the UHT production lines. “But most importantly, it is really hygienic.” Continuous processing What does an oil refinery have in common with a beverage or food processing plant? Not a lot. But for some food and beverage processing plants, the commonality might be more observable—that is, if a particular application lends itself to continuous processing/blending instead of batch processing. Of course, there are a lot of “ifs,” but, according to Dillon, if a process can be converted from batch to a continuous blending system, there are a lot of savings—time, space, energy and money. The controls are available, pump technology now includes metering devices, and the sensors/transmitters are available to close the control loop. Dillon already has carbonated beverage customers and even dog food processors that are adopting this technology. Dillon says he is already supplying skid manufacturers with pumps to design and build continuous blending systems. Wittkoff calls this process “inline formulation,” and for applications that lend themselves to this technology, the pluses are: Mixing tanks are no longer needed; batch processes no longer need to run, but are converted to a continuous process; formulated product goes straight to filling/packaging, eliminating holding vessels; and in the conversion, floor space is freed up with the elimination of

mixing/holding tanks and vessels. The system allows for quick changeovers and the elimination of several steps. The biggest drawback, Wittkoff says, is that pumps still have too much slip to provide a consistent process with some liquids. Nevertheless, products that work well with this scenario are toothpaste and certain pet foods where viscosities are greater than 1cps. This continuous blending concept has already been applied successfully in certain pharma and bio-pharma applications, says Matt Glicken, VP sales and marketing, SensiBlend. SensiBlend, a maker of skid-based systems using all of the pumping, metering and controlling techniques already described, is finding interest in CPG and beverage applications. Glicken says FDA’s Process Analytical Technology (PAT), which was conceived for pharma, is used in this continuous process system and automatically builds in regulatory compliance, making it applicable for food and beverage as well. In a continuous blending system, smart sensors measure both chemical and physical properties of the product against preset standard values. The system software adjusts proportioning onthe-fly, based on these measurements, to guarantee product quality, adds Glicken. With an inline, real-time system, quality control is integrated into the process. Less waste and simplified production are among the advantages of a system that can be employed for functional beverages, soft drinks and other products. While energy savings plays a subservient role to maintaining the quality of product as it’s being pumped, nevertheless, the right pump for the right application—whether centrifugal or PD—can change the energy-savings picture significantly. In this era of constrained budgets, maintaining product quality and saving energy don’t have to be mutually exclusive. ❖

Clyde Smith, Fluid-o-Tech, 860-276-9270,

Chuck Treutel, Watson-Marlow, 608-883-6851,

[email protected]

[email protected]

Michael Dillon, seepex Inc., 937-864-7150,

Matt Glicken, SensiBlend, 203-858-0032,

[email protected]

[email protected]

Wallace Wittkoff, Pump Solutions Group-Wilden/

Darryl Wernimont, POWER Engineers, Inc.,

Mouvex, 909-722-1900, [email protected]

904-318-7186, [email protected]

Chad Hawkins, Alfa Laval, 262-605-2600,

Sam Raimond, Fristam Pumps, 608-203-2041,

[email protected]

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www.foodengineeringmag.com | Food Engineering | October 2011

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FIELD REPORTS

Snack food maker cleans up its wastewater

`

Membrane bioreactor system eliminates $100,000 in monthly municipal surcharges. olden Flake Snack Foods (Birmingham, AL) was faced with a tough decision—either come up with a solution to stop escalating municipal wastewater surcharges, or move its 300,000-sq.-ft. snack food processing plant out of the county to stem the rising costs. In 2008, costs had escalated to $100,000 per month in surcharges, with county projections of up to $250,000 per month by 2014. The Alabama Department of Environmental Management (ADEM) made it clear that if Golden Flake could reach prescribed TSS (total suspended solids), BOD (biochemical oxygen demand), NH3-N (ammonia-nitrogen) and DO (dissolved oxygen) concentrations, it could receive a discharge permit to convey treated effluent directly into a creek that runs along the perimeter of its property, and bypass the Jefferson County sewer system. The Golden Flake plant manufactures and distributes a full line of snack food items, including potato chips, tortilla chips, puffed corn, corn chips, cheese puffs, cheese curls, onion rings and pork skins. In 2009, Golden Flake’s Birmingham facility processed more than 20 million pounds of snack foods.

G

` This is a view into the bio-reactor at Golden Flake. Covers are normally kept on to keep leaves and other debris out of the system. Source: ADI Systems.

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October 2011 | Food Engineering | www.foodengineeringmag.com

Raw snack food wastewater is pumped through vibrating screens that collect 15,000 to 20,000 pounds per week of large food particles. This organic matter is collected and transported upstate to be used as animal feed. “The wastewater being decanted to the county sewer system had BOD and TSS concentration levels in the thousands, exceeding maximum surcharge levels” says David Jones, Golden Flake executive vice president of operations. “As our surcharges continued to escalate, we began looking for a treatment technology that could not only handle our high-volume peak flows of 350,000gpd, but also produce an effluent that was below ADEM’s maximum allowable discharge concentration limits for BOD, TSS, NH3-N and DO.” Golden Flake brought in ADI Systems to engineer a solution, which was complicated by the fact the inner-city plant is landlocked. There was no room for site expansion, and little space for a conventional activated-sludge facility. ADI Systems recommended a membrane bioreactor (MBR) system to treat the raw wastewater following the vibrating screens. The ADI-MBR process, based on technology developed by ADI Systems and Kubota Corporation, is a form of activated sludge technology that uses a submerged membrane barrier to perform the liquids/solids separation and reactor biomass retention functions, instead of gravity clarification, which eliminates problems associated with sludge settling and separation. The new MBR system consistently produces effluent that is lower than the discharge limits set by ADEM. Up to 250 gallons per minute of clean, highquality effluent is released into Upper Valley Creek, and serves to enhance the downstream riparian environment by improving the oxygenation of the water flow within the small watercourse. The waste-activated sludge from the MBR system is pumped through an onsite dewatering press to reduce the overall sludge volume to 20,000 pounds per week, which is then trucked upstate for farm fertilization.❖ For more information: Graham Brown, ADI Systems Inc., 506-452-7307; [email protected]; www.adisystemsinc.com

FIELD REPORTS

Vibratory sifting improves brownie throughput

`

Brownie baker upgrades its homebrew screener to keep up with increasing orders.

G

reyston Bakery has an unusual history for a commercial bakery. It was founded in 1982 as the for-profit arm of the Greyston Foundation, which uses the bakery’s earnings to fund community development initiatives. Greyston Bakery has been baking brownies for blending with ice cream since 1988. Since then, it has grown into one of the industry’s top suppliers, producing more than 20,000 lbs. of ice cream mix-ins daily. “Our 23,000 sq.-ft. facility is in an urban location where storage is at a premium, so we keep only minimal inventories. Every step of the production process needs to keep up the pace. We ship them as fast as we cook them,” adds Vincent Lombardo, plant engineer. After mixing, baking, cooling and sizing brownies, pieces intended for single-serve cups move to the vibratory screener, where chunks larger than 0.25 in. x 0.25 in. are removed. Greyston’s first vibratory screener was a tray-in-a-tray box model driven by two rotary air vibrators built in-house by Lombardo. It was unable to keep up with the flow of production.

` Particles larger than 0.25- x 0.25-in. square discharge through an upper spout, on-size particles move through lower spout. Source: Kason.

“It was not robust enough to handle 20 hours per day of production,” Lombardo says. “We considered going with either a rotary or a vibratory screener. We eventually decided on the circular vibratory screener because of its low maintenance requirements, screen longevity, capacity and price.” Lombardo specified a 24-in. diameter Vibroscreen circular vibratory screener from Kason Corporation. The gravity-fed, food-grade unit is driven by a single, low-horsepower, 230-volt three-phase, imbalancedweight gyratory motor mounted in an enclosed cage directly beneath the screening chamber. Due to height limitations, the Vibroscreen screener is limited to one screen deck, yet it meets throughput requirements while offering reserve capacity. When the brownies enter the screener, multiplane inertial vibration of the nylon screen causes the 0.25-in. square pieces to fall through its apertures. Larger chunks are transported across the screen surface along controlled pathways into the discharge spout, which ejects them onto a conveyor that takes them for regrinding. “We opted for only one screen, since we’re more concerned with removing oversized pieces than removing any fines that were not removed by the tumbler,” says Lombardo. “If we needed to, we could drop the 0.25-in. square pieces onto a 10 mesh screen and remove any fines that fell through.” Instead, the 0.25-in. square pieces drop onto a pan and exit past a vertical metal detector. If the detector senses any slivers of metal in the brownies, the batch is discharged automatically through a cylinderactivated chute and discarded. While blinding is not an issue, the screener requires daily cleaning. “We run production for 20 hours, then shut down for four hours to clean the whole system,” says Lombardo. “The motor and connector box are watertight, so we can rinse down the interior and exterior with a hose, apply a foaming cleanser and then rinse it down again,” he explains. ❖ For more information: Henry Alamzad, Kason Corporation, 973-467-8140 or [email protected]

www.foodengineeringmag.com | Food Engineering | October 2011

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PROCESS EXPO 2011 Practical solutions, expanded conference

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hile PROCESS EXPO 2011 promises more than 400 exhibitors and has surpassed last year’s exhibit floor space, the expanded roster of conference sessions will provide real-world, practical solutions for a wide variety of plant production issues. The conference sessions run from Tuesday, November 1 through Friday, November 4, 2011 and will be held at McCormick Place South in Chicago, IL. Exhibits are open from 9:00 a.m.-5:00 p.m. Tuesday through Thursday and from 9:00 a.m.-2:00 p.m. on Friday. For Spanish speakers, a special conference program, “Seminario de Innovaciones,” runs on Monday, October 31. As the Food Safety Modernization Act (FSMA) gets into high gear, this conference offers plenty of help with food safety issues: from HACCP to various methods of sterilization and sanitary methods plus the management of pathogen risks. In addition, several sessions deal with plant efficiency, sustainability and energy savings. Show management stresses that attendees should register specifically for sessions they want to attend. Registration can be done online at www.myprocessexpo.com. Here is a quick rundown of the conference topics: Tuesday morning (Nov. 1) features three concurrent 11:00 a.m.-12:00 p.m. sessions: “Great Green Gobs of Opportunity at Food & Beverage Facilities: Anaerobic Membrane Bioreactor to Treat High-strength Waste Streams,” “Strengthening Your HACCP and Food Safety Program” and “Preventive Programs in the Meat Industry for Perfection in Food Safety.” Tuesday afternoon (1:15-2:15 p.m.) includes “Novel Food Processing Technologies: Update on Emerging Applications, Research and Regulations” and from 2:30-3:30 p.m.: “Defrosting Pork, Turkey and Chicken without Purge Loss” concurrently with “Totally Integrated Automation.” Wednesday morning (8:30-9:30 a.m.) features four concurrent meetings: “Upgrade Your Biogas to Valuable Pipeline-grade Renewable Natural Gas,” “Food Safety in Beef: Focus on E. coli O157:H7 and Other Non-O157 STECs,” “High-accuracy Feeding and Handling of Food Ingredient Macros and Micros” and “Bakery Challenge: Working with Legacy Infrastructure and Equipment in the FSMA Era.” One session will be held in the 10:00-11:00 a.m. time slot: “The 4 Elements of an Effective Food Safety Management System.” From 11:00 a.m.-12:00 p.m., visitors can attend “Innovation Driven by Customer Needs” and “Motor Control Centers—Using Siemens Motor Controls Online to Increase Your Plant’s Productivity and Flexibility.” Wednesday afternoon (1:15-2:15 p.m.) includes three concurrent sessions: “Hiring and Retaining Employees,” “Easy,

Clean and Sanitary Design Options for Mixers and Agitators” and “Building Preventive Maintenance Programs to Save Money and Enhance Efficiencies.” Two 2:30-3:30 p.m. concurrent sessions include “The Promises and Challenges of Applying High-pressure Pasteurization for RTE Food Products” and “Innovations in Cartoning Technology.” Thursday morning features four concurrent sessions from 8:30-9:30 a.m.: “Better, Faster, Cheaper … Can You Have All Three?” “Consider Utilizing Concentrated Solar Power, Compact Linear Fresnel Reflector Technology as a Source for Heat,” “How to Improve Food Processing Plants’ Efficiencies by Focusing on Unconventional Areas” and “Electrolyzed Water: A Sustainable Technology for Cleaning and Sanitizing.” “New FDA Food Safety Modernization Act—Implications for Food Processors” runs from 10:00-11:00 a.m. Two 1:15-2:15 p.m. concurrent meetings run Thursday afternoon: “Food Safety and Brand Protection through Technology” and “Green Sustainable Technology: The Past 10 Years. The Next 10 Years.” At 2:30-3:30 p.m. “An Integrated Approach to Process Facility Design, Engineering and Construction” takes place. Friday morning features three 8:30-9:30 a.m. concurrent sessions: “Novel Food Processing Technologies: Update on Emerging Applications, Research and Regulations,” “Building Preventive Maintenance Programs to Save Money and Enhance Efficiencies” and “The Value of 3-A For You.” From 10:00-11:00 a.m., visitors can attend “Managing Pathogens Risks in Dairy Operations.” The conference concludes with a single 11:00 a.m. session: “Strategies for Water Reuse in the Food & Beverage Industry.” ❖ www.foodengineeringmag.com | Food Engineering | October 2010

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2011 PROCESS EXPO SHOW Previews Special Advertising Section

A&B Process Systems Corp.

Schenck AccuRate Schenck AccuRate is a complete solutions provider for weighing and feeding dry ingredients or additives for food manufacturers. Focusing on our customer’s needs we’ve invented and continue to advance bulk solids material handling products and systems that have a proven track record for accuracy, reliability, price efficiency, and quality.

A&B Process Systems is a proven leader in the design, fabrication, automation, testing and installation of high quality stainless steel process skids/super skids, tanks, auxiliary equipment and piping systems. A&B has eight plants in Stratford, Wisconsin, with over 250,000 square feet of manufacturing capacity including its controlled environment facility that prevents the contamination of high purity tanks & systems. Since 1973, A&B has steadily grown to 450 associates and become a strategic supplier to many Fortune 500 Companies in the pharmaceutical/personal care, food/beverage, dairy, and industrial/renewable energy industries. A&B has the internal resources to execute a project from concept to completion. A&B’s “make it happen” attitude helps it stand apart from its competitors by reducing overall project costs and improving lead times. A&B works directly with its clients, or if desired, their contracted engineering firms to ensure the process systems and equipment are designed to match the client needs and the installation requirements. A&B’s efforts are supported by an inhouse staff of design and automation engineers, welders, fitters, QA/QC professionals and project management personnel. From concept to completion, A&B can ensure your success through every phase.

Our award winning MECHATRON® feeder is used in food manufacturing applications where the need to feed materials like flours, colors, preservatives, fruits, spices, and sweeteners are required. Offered with either a Coni-Flex™ flexible hopper or in all stainless steel the feeder has the unique ability to be disassembled, cleaned, reconfigured, and serviced from the non-process side. 3-A sanitary models with wash down motors, electropolished frames, and FDA accepted white polyurethane internal feed hoppers are also available. Additionally, we have recently released the new DEA Sanitary Open Frame Weighbelt Feeder. The new weighbelt is designed with all the necessary features for maintaining sanitary processes including, tool-less, rapid belt removal for frequent cleaning cycles, IP69K stainless steel load cells manufactured to withstand high pressure spray, a shaft mounted, wash-down drive system for simple power transmission, and product contact surfaces with 316 stainless steel. DEA Sanitary Open Frame Weighbelt Feeders provide weight controlled feeding, weight indication and totalization for fragile materials like cereals, snack foods, kibble, fruits, and pasta. Other features include accuracies of ± 0.25% to 1% of set rate sigma, BIC (belt weight influence compensation), and model sizes in 12” and 24” belt widths. Please see Schenck AccuRate at booth number 4715 for all your dry material weighing and feeding needs.

116

Contact: Andrea Wiese 201 S. Wisconsin Ave. Stratford, WI 54484 Phone: 715-687-4332 Fax: 715-687-3225 www.abprocess.com

Contact: Schenck AccuRate 746 E. Milwaukee Street Whitewater, WI 53190 262-473-2441 E-mail: [email protected] Web site: www.accuratefeeders.com

See us at PROCESS EXPO Chicago booth #2112

See us at PROCESS EXPO Chicago booth #4715

October 2011 | Food Engineering | www.foodengineeringmag.com

2011 PROCESS EXPO SHOW Previews Special Advertising Section

Admix

We’ll be there! Come see what’s new! Since 1989, Admix has been recognized as a leader in Advanced Mixing Technologies for high performance, high efficiency sanitary mixing systems and for our commitment to innovation and high quality. Our experience has led us to develop a diverse product line to meet any mixing challenge — with a special focus on adding powders into liquid. We offer a full range of products for inline mixing and milling, powder induction, as well as in-tank batch processing. Partnering with Admix provides complete access to our expertise and our fully equipped pilot lab. That means your new products will move from development to full production faster and more cost efficiently. Admix is excited to announce that we’ll be introducing TWO NEW PRODUCTS at the Process Expo in Chicago this fall! Stop by and visit us at Booth #423 and see what’s new!

A M King A M King is a full service Design Build and Construction Services Company operating out of Charlotte, NC providing services throughout the United States to the food manufacturing and distribution industry. A M King has a uniquely successful approach to the development and construction of their client’s projects. By focusing on client relationships where they become a true business partner, the team at A M King has consistently delivered the best value and the highest quality of services to corporations throughout the United States. They work with their clients to best understand their corporate culture and project expectations. This approach has allowed A M King to successfully design and construct over 7 million square feet of food manufacturing and food distribution facilities in just the past 7 years and are on track to have 8 million square feet in 8 years.

Contact: Peter Leitner, Meat & Poultry Market Manager [email protected] 603-627-2340 http://www.admix.com/meat.htm

Contact: A M King Construction Company, LLC 1610 East Morehead, Suite 200 Charlotte, NC 28207 P: 704.365.3160 [email protected] www.amkingconstruction.com

See us at PROCESS EXPO Chicago booth #423

See us at PROCESS EXPO Chicago booth #108

www.foodengineeringmag.com | Food Engineering | October 2011

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2011 PROCESS EXPO SHOW Previews Special Advertising Section

AmeriVap Systems

Anritsu Industrial Solutions

AmeriVap Systems is the recognized leader in dry-steam vapor technology. We have the experience to innovate and provide chemical-free sanitation solutions for your most challenging situations. AmeriVap introduced superheated steam cleaning to the United States in 1990 and we continue to develop technologies, products, applications and tools that save time and money with absolute respect for the environment. We’re always learning from experience and never too busy to listen when a customer needs a solution. Xtreme Steam, AmeriVap’s industrial product line, is a completely green technology that makes sanitizing possible in an environmentally friendly way without the use of harsh chemicals. Our culinary-grade super-heated, saturated, dry steam vapor products can actually increase your sustainability while saving you money on water, chemicals, labor and costly production downtime. Our dry steam vapor equipment can be used as part of a Green Cleaning Program when pursuing USGBC’s LEED Certification. No matter which level of certification you seek, AmeriVap’s dry steam vapor technology can contribute to LEED GBOM Indoor Environmental Quality Credits 3.1 and 3.4. AmeriVap’s culinary-grade superheated dry steam vapor sanitizing technology is faster, cleaner, and more effective at eliminating harmful bacteria, germs and pathogens than traditional cleaning methods. The Xtreme Steam generators are completely self-contained, and use only quarts of water as opposed to gallons, with little to no water residue. When coupling the Xtreme Steam generator with our exclusive and patented Houdini conveyor belt cleaning equipment, the system provides the ideal solution for cleaning and sanitizing plastic mesh, wire or flat surface conveyor belts in-situ, leaving them clean, dry and sanitized, while not affecting production time. The Xtreme Steam product line excels in many areas of Food Processing including: • Wrappers, slicers/dicers, scales/sensors • Conveyors/chains, belts, sprockets, rollers, feeders, gaskets and racks • All sensitive packaging equipment • Corrective action • Electrical panels and fixtures • Micro sampling • Robotics • Data trace probes • Drains • Most any hard to reach area • Overhead pipes • and more • Refrigeration systems • Degreasers

Anritsu Industrial Solutions, a leader in X-ray inspection systems, continues to push the envelope with the development of its innovative Dual X technology. Developed to enhance the performance of its KD7400 line of X-ray Inspection Systems, Anritsu’s Dual X technology minimizes product effect and provides a more exacting means of detecting bones and other lowdensity items. Typically, the closer the contaminant’s density is to the food product, the harder it is to detect. Anritsu’s Dual X technology differentiates between product and contaminant by analyzing two separate x-ray energy signals. It enables a higher detection rate of low-density items compared to conventional X-ray technology. Anritsu’s exclusive Dual X Anritsu’s Dual X Technology technology is ideal for use in the poultry industry, where bones are exceptionally difficult to detect. It is also well suited for detecting glass and stone in bulk nuts/grains and for items 50mm high or less (hamburger patties, sausage links, granola bars and more). Based on the Six Sigma Concept for zero defect quality and BACT (Best Available Control Technology), Anritsu continuously develops innovations that improve the performance of its line of X-ray inspection systems. For instance, Anritsu’s High Definition (HD) X-ray technology automatically and simultaneously detects contaminants, underweight conditions and other packaging anomalies. Applications can vary from scanning for bone or hypodermic needle fragments in meat products to detecting wire fragments, glass or stone in traditional food packages. Anritsu Industrial Solutions offers a full line of inspection equipment including its advanced X-ray systems (6,000 installed) exclusive Dual Wave (DuW Series) Metal Detectors (over 45,000 installed), and a wide variety of checkweighing solutions (over 60,000 installed). Anritsu products are HACCCP-compliant.

Contact AmeriVap today to learn more about the solutions and benefits our dry steam vapor equipment has to offer you.

BEFORE

AFTER

DETECTION PERFECTION Contact: Anritsu Industrial Solutions USA Inc. 1001 Cambridge Drive, Elk Grove Village, IL 60007, Phone: (847) 419-XRAY (9729), www.detectionperfection.com Email: [email protected] See us at PROCESS EXPO Chicago booth #1960

See us at PROCESS EXPO Chicago booth #150

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2011 PROCESS EXPO SHOW Previews Special Advertising Section

Arizona Instrument LLC

Beckhoff Automation

Computrac® moisture determination provides a method of moisture analysis by utilizing rapid Loss On Drying (LOD). Our instrumentation is designed for lab precision and production durability. The four-place balance, nickel chromium heating element and built-in cool down fan make our newest LOD instrument, the MAX® 4000XL fast, accurate and repeatable. Set up a free trial by stopping by Process Expo Booth #1952 or contact our sales department at 800.528.7411 or [email protected].

Beckhoff Automation Introduces New Food-Grade Servomotors Dynamic AM3000 servo motors in new wash-down variant

Features Accuracy, Durability, Reliability, Consistency and Speed Fan-Assisted Cool-Down provides 25% higher throughout Color LCD Display Programmable Temperature Ramp Control Four Decimal Place Balance 21 CFR Part 11 Compliant USB and Ethernet Ports Parameter Expert Web Browser

In order to provide advanced motion solutions for the most demanding environments, Beckhoff Automation has released new food-grade AM3000 Synchronous Servomotors. These new FDA-compliant servomotors are designed with a resistant white surface coating making them ideal for food and beverage manufacturing, packaging and any application that requires wash-down. A further advantage, the coating adds only about 30 percent to the price of the standard versions of the servomotors, depending on the size. The coating is well-suited for use around food products and is resistant to aggressive cleaning agents. Apart from the surface coating and stainless steel shaft, the motors do not differ from the standard offerings in Beckhoff’s high performance AM3000 series. The advantage for the user is that additional motor types do not have to be ‘designed into’ the machine in the case of mixed use of coated and standard motors. Hygiene regulations in the food industry place high demands on drive and control components with regard to surfaces and materials, which must be able to withstand regular exposure and resistance to aggressive cleaners. By coating a standard servomotor to make it suitable for use around food products, Beckhoff breaks new ground: the protective white coating, which is typical in the food industry, is compliant with FDA regulations and guarantees that the products manufactured with it are not in any way tainted by chemicals when proper wash-down procedures are followed. Additionally, the IP 67 design permits use in other harsh industrial environments. Flange sizes 2…7 from the Beckhoff AM3000 series are available with this new optional surface coating.

Contact: Rick Ervin, Director of Sales email: [email protected]

Contact: Beckhoff Automation LLC Phone: 952-890-0000 Fax: 952-890-2888 e-mail: [email protected] www.beckhoffautomation.com

See us at PROCESS EXPO Chicago booth #1952

See us at PROCESS EXPO Chicago booth #415

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Bunting Magnetics Co.

Bühler Inc. Bühler Preconditioner POLYtherm™ BCTC The Bühler Preconditioner POLYtherm™ BCTC provides cost-effective broad spectrum capabilities for raw material conditioning and mixing prior to extrusion. This unique top-fitted design allows for easy attachment to the extruder, and saves crucial manufacturing space. The core feature of completely separate mixing and retention zones allows for precise control, as well as easy access for complete sanitation. In addition, this multifaceted machine can significantly reduce extrusion costs through reduced torque of up to 50%. Innovative Extrusion Processes without Limits Bühler is a global leader in the field of process engineering, focused on production technologies for food and engineering materials. Our extensive extrusion expertise and passion for customized solutions makes Bühler the superior choice, bringing value-added services and success to your brand. Bühler offers a complete production line from start to finish — whether breakfast cereals, snack foods, modified flours, starches or texturized proteins. Our engineers design the most current innovations in food production. From raw material Bühler offers tailored customer handling, cooking, shaping, extrusion and drying, Bühler workshops and training, either has the tailored solutions that fit on site or at Buhler’s extrusion your unique needs at every point pilot plant. in the process. This expertise, combined with unrivalled after sales support, customer service, and training, equals innovative extrusion processes without limits.

Contact: Bühler Inc. P. O. Box 9497 Minneapolis, MN 55440 (763) 847-9900 [email protected] www.buhlergroup.com See us at PROCESS EXPO Chicago booth #4236

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Bunting® Magnetics has strengthened its’ world class lineup of metal detection equipment with the addition of the Meatline 05 0 Metal Detector. The Meatline is designed for integration in vacuum fillers to examine liquid and pasty type of food products. It detects and separates any type of metal, encapsulated or free. “First of all, when it comes to detecting contaminants in food products, sensitivity is the key,” stated Rod Henricks, Bunting® Product Manager – Metal Detection. “The Meatline is unrivaled in providing the highest possible sensitivity with little interference. It features the latest technology and software and easily handles any product in a paste form.” The Meatline 05 0 features a reject mechanism which can be taken apart in a few easy steps without the need for tools. All components are linked together with a chain so they cannot get lost. After cleaning, everything easily fits together again. “The reject mechanism is the game changer for food processors, “Henricks said. “Cleanups are a breeze which is critical to keep a production line moving. Also, you can’t lose any of the parts. Since they are linked to each other, it is simple to reassemble.” The Meatline fits all commercial vacuum fillers. It is pressure washer safe and has a stable frame with lockable casters. The Meatline allows for easy operation through a Touch Screen Display which has a selfexplanatory menu structure. All components are made of stainless steel or food-safe plastic. It features a permanently maintenance-free pneumatic drive for a long lifespan.

Contact: Rod Henricks Product Manager - Bunting Magnetics Co. 500 South Spencer Road Newton, KS 67114 316-284-2020 [email protected] www.buntingmagnetics.com See us at PROCESS EXPO Chicago booth #3640

2011 PROCESS EXPO SHOW Previews Special Advertising Section

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

Contact: Caroline Cooper Burns & McDonnell 9400 Ward Parkway Kansas City, MO 64114 816-822-3831 [email protected] www.burnsmcd.com/fcp See us at PROCESS EXPO Chicago booth #4631

Clarion Lubricants Clear. Safe. Solutions. Clarion Lubricants. Clean and pure, clear and simple – Clarion Food Grade Lubricants have represented the leading edge of purity and performance for more than 40 years. Clarion food grade white mineral oils are so refined and stabilized that they can be used for everything from food coatings to direct use in pharmaceutical products like suntan lotions and ointments. Clarion’s diverse line of food grade lubricants that are registered NSF H-1 and Kosher offer solutions to almost any food manufacturing need. Food processing solutions include: • Food machinery oils • Compressor oils • Food grade greases • Synthetic lubricants Clarion Food Grade Lubricants are available through local retailers and online at www.clarionlubricants.com. To learn how the full line of Clarion Lubricants can provide superior performance and protection, contact info@clarionlubricants. com or call 855-MY-CLARION.

Contact: Name: Clarion Lubricants Address: 1293 Eldridge Parkway, Houston, TX 77077 Phone: 855-MY-CLARION (855-692-5274) URL: www.clarionlubricants.com Email: [email protected] See us at PROCESS EXPO Chicago booth #1740

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CPM Wolverine Proctor

Douglas Machines Corp.

CPM Wolverine Proctor offers a complete line of energy efficient equipment to processors of vegetables, fruits, snack foods, nuts, readyto-eat-breakfast foods and more, including conveyor dryers, roasters, toasters, fluidized bed dryers and coolers, impingement ovens (jet-tube or parajet nozzle design), cereal flaking roll mills, and shredding and forming systems.

Douglas Machines Corp. offers

CPM Wolverine Proctor Equipment Highlights:

used in the food processing and

Multi-Stage and Multiple Conveyor Dryers are designed for maximum capacity using minimum floor space. Unique air circulation patterns, multiple air direction reversals, and multiple temperature and humidity control zones, produce the most uniformly dried products possible. Impingement Ovens - Jet-Tube or Parajet Nozzle design for baking, roasting, cooking & browning. Precise air control on top and bottom of product for maximum uniformity. Rugged, sanitary, unit welded construction minimizes cleaning. A Variety of air delivery systems available to help develop different product profiles. JETZONE Fluid Bed Dryer/Puffer/Toaster is a unique jet-tube fluidization dryer that offers the best solution for manufacturers of most flaked, pelletized, granulated, extruded and coarse powdered products. CPM Wolverine Proctor Tech Centers offer both continuous and batch testing. Engineers and process technologists are available to test and evaluate a wide range of products and materials. With over a century of experience and expertise in customer service, CPM Wolverine Proctor offers parts and service for what it sells and for other drying equipment brands as well.

Contact: CPM Wolverine Proctor 251 Gibraltar Road Horsham, PA 19044 Tel: 215.443.5200 Fax: 215.443.5206 Contact: Paul Smith Email: [email protected] www.cpmwolverineproctor.com

See us at PROCESS EXPO Chicago booth #1727

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

or

visit

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

Contact: Douglas Machines Corp. 2101 Calumet Street Clearwater, FL 33765 Phone: 800-331-6870 or 727-461-3477 Fax: 727-449-0029 Email: [email protected] www.dougmac.com See us at PROCESS EXPO Chicago booth #4208

2011 PROCESS EXPO SHOW Previews Special Advertising Section

Dur-A-Flex, Inc.

Evergreen Packaging Stop paying for floors that don’t perform!

Every couple of years, you plan for shutting down production and paying to repair your floors. Worn, eroded epoxy floors become trip hazards and start to fail section by section. Hard to clean grout lines allow for places for foodstuffs and bacteria to form, providing the conditions that lead to floor repairs and replacement. Dur-A-Flex will help you stop replacing floors so soon and eliminate the loss of production and revenue caused by downtime, constant repairs and total floor replacements. Our urethane system is the new industry standard for food processing flooring. This ultra durable, seamless, resinous flooring outperforms epoxy and tile because it was specifically formulated to handle the harsh, food processing environment. It easily resists the erosion caused by food acids, grease and moisture that team up and contribute to the growth of damaging bacteria. Dur-A-Flex flooring can help you knock out: • Revenue loss – quick installs to reduce downtime • Floor failure – seamless means no grout to maintain or places for bacteria to hide • Excessive wear and tear - caused by forklift/pallet jack traffic • Liability risks – reduce slip or trip hazards

Evergreen Packaging Expands Equipment Portfolio CEDAR RAPIDS, IA, USA – Evergreen Packaging Equipment will feature their complete line of gable top fillers in booth 2448. The company’s recent new product introductions include the ENHT-100, N-100, Q-70, EQ-70, and the Q-35. Beverage manufacturers gain flexibility with quick and easy changeovers to fill volume and carton heights. Servo-driven technology provides repeatable package performance to maximize production. The machines are easy to operate and maintain, reducing downtime. The low infeed loading height provides an ergonomic design for operator comfort and ease of loading. The operator can quickly and easily make changes to fill volumes to maximize production. The ENHT-100 and the N-100 serve the school milk, single serve food service and convenience store markets. With fill volumes of 4 to 16 oz (125 to 500ml), the new Eco-Pak® machines fill 4 to 10 oz. (125 to 300ml) cartons up to 10,200 cph (170 cpm) and 12 to 16 oz. (350 to 500ml) up to 8,500 cph (142cpm). The Q-70 and EQ-70 serve the mid-size volume market. With fill volumes of 6 to 32 oz (180ml to 1.15L), the machines fill quarts/liters up to 7,000 cph (117 cpm) and fractionals up to 9,000 cph (150 cpm) to meet market demand for a mid-speed quart/liter cross-section machine. The ENHT-100 and the EQ-70 feature ELL® (Extended Long Life) components including CIP/SIP system, environmental control features, carton decontamination and a hermetic filling system to maintain product quality. The Q-35 machine serves the small volume market. With fill volumes of 6 to 32 oz (180ml to 1.15L), the Q-35 fills quarts/liters up to 3,500 cph (58 cpm) and fractionals up to 4,500 cph (75 cpm) to meet market demand for a slow speed quart/liter cross-section machine. Evergreen machines can be equipped with four optional levels of machine and carton sanitization to maximize the shelf life of milk, specialty milk products and still beverages. An optional SPOUT-PAK® System is also available.

Contact: Dur-A-Flex, Inc. 95 Goodwin Street East Hartford, CT 06108 Tel: 860.528.9838 Fax: 860.528.2802 E-mail: [email protected] www.dur-a-flex.com

Contact: For more information, contact Evergreen Packaging Equipment at 319-399-3306 or visit www.evergreenpackaging.com.

See us at PROCESS EXPO Chicago booth #2954

See us at PROCESS EXPO Chicago booth #2448

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Fristam Pump

Fristam Pumps USA manufactures high-performance, stainless steel pumps, blenders and mixers. Fristam’s booth features the new FKL A positive displacement pump series with clean, rounded exterior; split-style gearbox for easy access to bearings and shafts; and customizable port-to-port dimensions for easy drop-in replacement of other PD pumps. The FKL A is built for no-disassembly-required “True CIP”. Its balanced rotors, large diameter shafts, and a heavy-duty gearbox make it durable and reliable. Additional products on display: Powder Mixer for quick and efficient blending of dry and wet ingredients into a fluid stream. FS shear blenders for inline mixing. FL II series PD pumps for gentle product handling. Easy-maintenance FPR series pump with front loading seal. Heavy-duty FP series centrifugal pump. Standard-duty FPX series centrifugal pump. High pressure pumps for discharge pressures to 1,250 PSI. FZX series self-priming pump for CIP return/aerated products.

Contact: Fristam Pumps USA 800-841-5001 www.fristam.com/usa See us at PROCESS EXPO Chicago booth #S2116

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Graco Inc. Graco’s complete line of SaniForce™ sanitary equipment can easily move a broad range of viscosities from fruit juices and pizza sauce to the most difficult materials like caramel and peanut butter. SaniForce piston pumps have pressure ratios up to 12:1 and are ideal for low to medium viscosity materials. The air motors improve serviceability and increase efficiency; the quick knockdown lowers are designed for fast and easy cleaning and are available in double ball or priming piston designs. The SaniForce air-operated double diaphragm pumps have flow rates up to 150 gpm (568 lpm) and are best suited for low to medium viscosity materials. All models are FDA-compliant and meet the CFR Title 21. Graco’s overmolded diaphragms virtually eliminate the risk of harboring bacteria, improve wear and are easy to clean. All models have a non-stick three-way pilot valve, and an externally serviceable air valve. 3A certifications are available. Graco’s drum unloaders can evacuate medium to high viscosity products from 55-gallon (208 l) containers, without diluting the material. The follower plate and inflatable wiper seal can achieve a 99% evacuation rate from straight-sided and tapered drums. Additional features include a liner guard to prevent bags from entering the pump and sanitary flange clamps for quick disassembly. Available with diaphragm or piston pumps. The SaniForce Bin Evacuation Systems™, with flow rates up to 100 gpm (400 lpm), eliminate manual scooping and bin dumping by unloading medium to high viscosity materials from 300-gallon (1135.6 l) “bag-in-bin” containers. The floating ram plate removes the need for exact positioning of bins under the ram plate and the inflatable wiper creates a tight seal preventing contaminants from entering the container. Available with diaphragm or piston pumps.

Contact: Graco Inc. 88 11th Ave NE Minneapolis, MN 55413 Phone: 1-877-844-7226 Fax: 1-877-340-6427 Email: [email protected] www.graco.com/sanitary See us at PROCESS EXPO Chicago booth #2048

2011 PROCESS EXPO SHOW Previews Special Advertising Section

IJ White Systems

Ingersoll Rand

With over 2100 systems worldwide, IJ White Systems offers a full line of Ultra Series Pouch Pasteurizing, Chilling and Blast Freezing for Soups, Stews, Puddings, Sauces, Gravy, Tomato Sauce, and Cheeses. A complete line of energy efficient Ultra Pouch Systems designed to uniformly pasteurize, cool or freeze hot filled products and are engineered to improve product quality and shelf-life.

Productivity and efficiency for every aspect of your business. Ingersoll Rand’s diverse and innovative products range from complete air compressor systems, tools, ARO pumps, material handling systems and more. Ingersoll Rand is committed to offering solutions to reduce your food safety risk, lower your cost of operation, and help you achieve your sustainability goals.

HOT / HOLD POUCH Pasteurizing: Designed to provide constant pasteurizing temperatures for pouches after filling. Utilizing steam or hot water in an all stainless steel insulated enclosure, HOT / HOLD provides uniform environment at constant temperatures. The system is designed to lower your energy costs and maximize the line throughput. These Ultra Series systems save valuable floor space and can handle a variety of different size pouches. HYDRO POUCH Chilling: Utilizing new chilling technology, the HYDRO POUCH CHILLER lowers internal product temperature faster and more uniformly by employing new intermittent Pouch Agitation Technology (PAT). Setting a higher standard, the system’s unique gentle handling prevents surface scarring or creasing of your pouches. HYDRO POUCH can even cool printed pouches without damage. AIR BLAST POUCH Chilling: Providing concentrated airflow across the product zone, AIR BLAST CHILLER is designed to cool pouches more uniformly than traditional coolers. Using the latest in Stainless Steel tube refrigeration coils for the superior hygiene, these systems are engineered to set a new level in sanitation. These Ultra Series Systems have available our patented Pouch Agitation Technology (PAT) which has proven to reduce chilling times and save energy. THERMAL POUCH Blast Freezing: This is the latest technology designed to reduce freezing time and increase your product’s shelf life. Ultra Series Freezers are available with our Continuous Production System (CPS) which allows long production runs and reduces defrost downtime. Engineered to deliver the best freezing performance, the system is the most energy efficient design for vertical form-fill-seal technology for today’s food processors. Contact: I J White Systems 20 Executive Blvd. Farmingdale, NY 11735 Tel: 631-293-2211 Fax: 631-293-3788 Contact: Karen Ossip Email: [email protected] www.ijwhite.com See us at PROCESS EXPO Chicago Booth #1448

Class Zero Air Quality ISO 8573-1:2001 Air Quality Classes Ingersoll Rand affords you the peace of mind that comes with knowing your compressed air is 100% free of compressor-created contaminants. Ingersoll Rand was the first to deliver ISO Class 0 in both rotary-screw and centrifugal technologies. Oil- free Air Compressors

EXPert Series Diaphragm Pumps ARO’s Process Grade Diaphragm Pumps feature the best total cost of ownership of any diaphragm pump. EXP Pumps provides optimum energy efficiency and minimize downtime. Featuring flow rates up to 275 GPM (1041 LPM) with a broad range of material and porting configurations. ARO Sanitary Transfer Diaphragm Pumps Ideal for food processing and chemical additives (food grade) applications where quick-disconnect fluid connections are required. Constructed of FDA accepted material.

ARO Sanitary Transfer Diaphragm Pumps

Tools For more than 100 years, professionals have relied on Ingersoll Rand tools for quality and performance on the toughest jobs. Ergonomic Lift Assist Devices Ergonomic Lift Assist Devices Our ergonomic lift assist devices are built to last and engineered to meet or exceed all ANSI specifications for safety and quality.

Air Hoist Ingersoll Rand air chain hoists are designed for trouble-free maintenance. The paintless MLK hoist is durable and proven for most food applications.

Contact: Ingersoll Rand 800 Beaty Street, Davidson, NC 28036 USA www.ingersollrandproducts.com See us at PROCESS EXPO Chicago booth #3808

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JAX INC. Founded in 1955, JAX INC. manufactures the industry’s highest-quality food-grade, synthetic, heavy-duty and general industrial lubricants. JAX has led the industry with recent advances in the areas of high-end synthetic and food plant lubricants. We use only the finest NSF-registered H1 synthetic base stock blended with stateof-the-art additive technology designed to decrease machinery downtime and reduce lubricant consumption in order to ultimately increase the life span of equipment. With our full line, JAX has existing products and also the industry expertise and experience to tailor our lubrication technology to your specific needs. Most notably, JAX revolutionary line of Halo-Guard® FG greases combines an advanced, proprietary calcium sulfonate complex thickener and new high-viscosity, partial and full synthetic food-grade base fluids in order to provide unmatched performance on heavily-loaded applications. While we may gain most recognition for our lubricants, JAX is truly a turnkey solutions provider, covering the full spectrum of your needs. Our industry-leading lubricants are only the beginning. Xact Fluid Solutions division engineers automated fluid-dispensing solutions tailored to specific requirements and plant applications. In addition, the Xact Lube-Guard Program offers a comprehensive approach to clearly identifying each lubricant, its proper application and the lubrication maintenance schedule in your plant. The process is guided by our color-coded wall charts, lube tags and safe storage containment systems. In JAX independent RPM laboratory, our technical staff recognizes the ever-evolving nature of lubrication technology and is relentlessly researching ways to improve our industry-leading product line. In addition, our used oil analysis program keeps your machines running smoothly by identifying internal component wear issues before unscheduled downtime takes a toll. JAX RPM Lab delivers exceptional turnaround time on received samples, reducing the worries associated with plant maintenance. Pressure-Lube Inc. manufactures the finest industrial aerosol maintenance products in the industry with a full line to meet the requirements of any application. In addition, JAX new food plant-friendly, color-coded packaging clearly identifies H1 products to take the safety guesswork out of lubricant selection. Add to this equation a staff of the most knowledgeable and dedicated people in the industry and the result is clear: at JAX, our full line of products and services will meet and exceed all your needs and our dedicated, professional people will be there with you all the way. Contact: JAX INC. W134 N5373 Campbell Drive Menomonee Falls, WI 53051 262-781-8850 Phone / 262-781-3906 Fax www.JAX.com See us at PROCESS EXPO Chicago booth #3417

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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.

Contact: JBT FoodTech 1622 First St Sandusky, OH 44870 (419)626-0304 www.jbtfoodtech.com [email protected] See us at PROCESS EXPO Chicago booth #615

2011 PROCESS EXPO SHOW Previews Special Advertising Section

Key Technology

K-Tron

As a leading manufacturer of process automation systems for the food processing industry, Key Technology helps customers improve product quality, optimize yield, reduce labor costs, and improve process control to enhance plant efficiencies. • Laser / Camera Sorting Systems – Manta® high volume sorters, Tegra® in-air sorters, and Optyx® compact sorters identify and remove defects and foreign material. OnCore® is an integrated system for processing of iceberg and romaine lettuces in bagged salads. ADR® for potato strips selectively cuts strips to length while also cutting out defects. • Specialized Conveying Systems – Iso-Flo® vibratory conveyors, Horizon™ horizontal motion conveyors, Impulse™ electromagnetic conveyors, SpiralFlo™ elevators, and pumping systems.

• Grading systems – Iso-Flo and Farmco equipment for sizing, grading, and separating. • Preparation Systems – air cooling, air cleaning, washing, and feeding. • Fresh-cut food processing equipment – washers, dryers, and integrated lines. • Services – application testing, custom engineering, line integration, installation and start-up, training, and customizable service packages for maintenance and repairs.

K-Tron’s Continued Commitment to Material Handling and Feeding Systems K-Tron is a global leader and single-source supplier of process automation equipment and engineered systems, including gravimetric feeding equipment, dense and dilute phase pneumatic conveying equipment, and complete turnkey systems solutions for the food, pet food, pharmaceutical, chemical, plastics, non-wovens and detergent industries. K-Tron holds more than 100 patents for feeding, weighing, mechanical and control technologies, offering bulk solids handling experience for batch and continuous processes for a variety of manufacturing industries worldwide. Stop by K-Tron Booth 3707 As part of the company’s material handling and feeding systems capabilities, K-Tron will demonstrate a system at the K-Tron Booth 3707 featuring ActiFlow™, a material flow aid that prevents bridging and rat-holing of cohesive materials in loss-in-weight feeder hoppers, the K-Tron Quick Change twin screw feeder, running in application with a K-Tron 2410 stainless steel vacuum sequencing receiver for sanitary pneumatic conveying applications. Also featured in the booth will be a fly-through animation video which provides food processors a look at K-Tron’s process automation solutions. Video highlights: • Rail and truck unloading • Pneumatic conveying to silo • Gain-in-weight batching (GIW) • Loss-in-weight batching (LIW) • Batching of major and minor premixes • Continuous mixing (LIW feeding and dense phase vacuum conveying) • Extrusion via LIW powder and liquid feeding

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

Contact: For more information visit: www.ktron.com/ProcessExpo E-mail: [email protected]

See us at PROCESS EXPO Chicago booth #1402

See us at PROCESS EXPO Chicago booth #3707

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Lubriplate Lubricants Company

Mepaco

Lubriplate Lubricants Company is a producer of high performance, long life, synthetic lubricants. These lubricants provide superior lubrication and protection for all types of industrial machinery, food processing and bottling machinery as well as construction, automotive and marine equipment. The company has executive offices in Newark, New Jersey and manufacturing facilities in Toledo, Ohio. Lubriplate Lubricants are backed by an international system of local distributors. The company is ISO 9001 Registered. Of special interest is the major market position Lubriplate enjoys in the field of food processing and bottling machinery lubrication. These Lubriplate NSF H-1 Registered lubricants meet FDA regulations 21 CFR 178.3570 and 21 CFR 172.882. They are certified OU Kosher Pareve and HALAL registered. The manufacturing process for these H-1 lubricants is ISO 21469 Compliant. The use of Lubriplate H-1 lubricants throughout your plant operations can significantly simplify your HACCP program by eliminating lubrication as a potential chemical hazard. Sales, marketing and technical staff can be reached at 1-800-733-4755 or e-mail [email protected]. Their webpage is www.lubriplate.com. Specific lubrication questions can be addressed to [email protected].

Contact: Mr. Jim Girard, VP & CMO Lubriplate Lubricants Company 129 Lockwood Street NEWARK, NJ 07105 1-800-733-4755 www.lubriplate.com See us at PROCESS EXPO Chicago booth #1609

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Process Expo Highlights from Mepaco As pioneers in the meat and food processing industries, Mepaco specializes in processing solutions for grinding, blending, cooking, and material handling challenges. Their comprehensive service and product offerings incorporate many pieces of standard machinery, system design & integration along with enhanced sanitary finishing and custom fabrication. At the 2011 Process Expo, among other things, Mepaco will be exhibiting their ThermaBlend™ line of cookers that features superior cooking, cooling, and blending characteristics. Constructed by ASME Certified Welders, ThermaBlend delivers long lasting reliability even after years of stress from large-scale cooking and cooling applications. Mepaco will also be exhibiting their 420V Continuous Vacuum Stuffer. The 420V pulls and maintains full vacuum while it gently agitates the product in its vacuum chamber to expose more area to deaeration, resulting in greater density and yield. It also prepares the product for gas or vacuum packaging with vastly improved color and shelf-life. In addition to the ThermaBlend and 420V, the company will have Grinders and MixerBlenders on hand at their booth.

Contact: Mepaco 200 W. Industrial Drive Beaver Dam, WI 53916 (920)356-7323 www.mepaco.net See us at PROCESS EXPO Chicago booth #1031

2011 PROCESS EXPO SHOW Previews Special Advertising Section

METTLER TOLEDO

PAUL MUELLER COMPANY

METTLER TOLEDO invites you to a total 360° Product Inspection experience with a chance to see how our solutions can look at your inspection challenges from every angle. Visit us in Booth 202 and learn how our solutions can increase efficiency, reduce manufacturing costs and improve the competitiveness of your business. METTLER TOLEDO provides in-line product inspection solutions for the packaging industry with CI-Vision machine vision inspection systems, Hi-Speed checkweighers, Safeline metal detectors and Safeline x-ray inspection systems. Our broad product inspection line ranges from very basic and economical systems to sophisticated, state-of-the-art systems with customized material handling solutions. Depending on your specific requirements, our systems can ensure perfect product presentation, verify package and label integrity, ensure weight range compliance, detect physical contaminants and inspect contents inside the closed package. Machine Vision METTLER TOLEDO CI-Vision inspection systems ensure that products consistently meet manufacturers’ quality standards and specifications resulting in perfect product presentation every time.

Paul Mueller Company, headquartered in Springfield, Missouri, was established in 1940. For over 70 years, we have been building a reputation as an outstanding manufacturer of stainless steel tanks and industrial processing equipment that make the customer’s process smoother, faster, and more reliable. Mueller® has evolved into a global process solution provider, offering manufactured equipment and components, integrated process systems, and expanded-scope construction. Our philosophy is simple: we are committed to meeting and exceeding our customers’ expectations of value by providing high quality equipment, excellent service, and complete process solutions. Mueller products are used in over 100 countries worldwide on dairy farms and in a wide variety of industrial applications, including food, dairy, and beverage processing; pharmaceutical, biotechnological, and chemical processing; water distillation; heat transfer; HVAC; heat recovery; process cooling; and thermal energy storage.

Checkweighing METTLER TOLEDO Hi-Speed dynamic checkweighing systems ensure 100% quality control, minimize costly giveaway and give you total peace of mind. Metal Detection METTLER TOLEDO Safeline metal detection systems prevent costly recalls by ensuring your products are free of ferrous, non-ferrous and stainless steel contaminants which can be introduced during processing. X-ray Inspection METTLER TOLEDO Safeline x-ray inspection systems can detect ferrous, non-ferrous, stainless steel, glass and stone contaminants, detect mass and check for missing or damaged product inside closed packages.

Large field-erected vessels, equipment installation, retrofit and/or repair of process systems, process piping, and turnkey design and construction of complete processing plants are services provided by Mueller Field Operations, Inc., a wholly owned subsidiary. Transportation of the Companies’ products and backhauls of material and components are handled by another wholly owned subsidiary, Mueller Transportation, Inc. Mueller has the technical expertise, innovative engineering, and manufacturing resources to implement a process system specific to your needs. Let us provide your process solution!

Contact: Mettler-Toledo Safeline 6005 Benjamin Road Tampa FL 33634 PH 800-221-2624 FX 813-881-0840 [email protected] www.mt.com/pi

Mettler-Toledo Hi-Speed 5 Barr Road Ithaca, NY 14850 PH 607-257-6000 FX 607-266-5478 [email protected] www.mt.com/hi-speed

Mettler-Toledo CI-Vision 2640 White Oak Circle, Unit A Aurora, IL 60502 PH 630-446-7700 FX 630-446-7710 [email protected] www.mt.com/ci-vision

See us at PROCESS EXPO Chicago booth #202

Contact: Jim Hall and Mike Veatch 1600 West Phelps Street • Springfield, Missouri 65802 Phone: 1-800-MUELLER • 417-575-9000 • Fax: 417-575-9669 http://www.muel.com • E-mail: [email protected] See us at PROCESS EXPO Chicago booth #1612

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Quickdraft

Reiser

Since 1953 Quickdraft has provided its customers with pneumatic conveying systems and exhaust systems specifically engineered to solve customer production problems and to enhance their productivity and profitability. Venturi At the core of Quickdraft’s offerings for both pneumatic Arrows in the blue airstream depict conveying and exhaust the injected air accelerating the systems is its venturi. With flow. Arrows in the red airstream the blower handling ambiindicate the material being conveyed. ent air and no moving parts in the conveying or exhaust duct, the venturi is a low-maintenance, dependable solution for a variety of applications. Pneumatic Conveying Systems Quickdraft’s pneumatic systems can safely convey edible and inedible product, scrap hot dog casings, packaging trim, cook-in bags, mechanically deboned meat residue or other material hundreds Hot Dog Casing Removal System of feet for further processing or disposal, with minimal operator interaction. Systems are designed for 24/7 operation and require little or no maintenance. Exhaust Systems Quickdraft’s venturi exhauster is an excellent solution where there are high-maintenance exhaust problems: where the exhaust is very hot or very cold, highly humid, highly corrosive or when the exhaust contains sticky particulates. With no moving parts in the air stream, the exhaust system is dependable requiring little maintenance. All components in contact Exhaust Filtration with the air stream are stainless steel. It is System an excellent exhaust solution for a variety of ovens, fryers, microwave ovens, and freezing tunnels. Our venturi can be paired with our grease demister which uses water and mechanical filtration to capture grease and other particulates in the air stream and prevent grease build-up on roofs.

Contact: Quickdraft 1-855-VENTURI [email protected] www.quickdraft.com Visit us at PROCESS EXPO Chicago booth #3715

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Reiser will feature live demonstrations of their complete line of processing and packaging equipment and solutions at Process Expo. Of special interest to food processors will be the versatile Vemag with various attachments allowing it to perform a range of applications. On display will be the Vemag Cheese Shredder and Portioner. This Vemag solution is ideal for dispensing precise portions of shredded cheese onto pizza and prepared meals. The system combines a Vemag Portioner with a Cheese Shred Depositor attachment. Cheese blocks and scraps are loaded into the Vemag’s hopper, where they are then shredded and portioned directly onto conveyed product. The shredded cheese is perfectly portioned and is deposited cleanly and evenly with no mess. Depositing consistent portions onto moving lines is easily accomplished. Reiser will also demonstrate its loaf forming and packaging line. This system features a Vemag HP30E with an MMP220 loaf former. The Vemag HP30E features an inline grinder that combines grinding and separating with forming and portioning. The MMP220 automatically places the ground meat onto paper where it is conveyed to a cutting blade. The vertical cutting arrangement cuts the ground meat into individual portions. The result is a product with a uniform shape and a consistent, accurate weight. The formed loafs are then automatically indexed and loaded into a Repak RE20 form/fill/ seal packaging machine. Also in action will be Ross traysealers, Supervac vacuum packaging machines, Holac Dicers, Seydelmann grinders, and AMFEC mixers.

Contact: 725 Dedham Street Canton, MA, 02021 (781) 821-1290 Fax: (781) 821-1316 www.reiser.com See us at PROCESS EXPO Chicago booth #2602

2011 PROCESS EXPO SHOW Previews Special Advertising Section

SIEMENS

SPX Flow Technology

No matter how high your goals, Siemens can help move your business forward with our technological experience, local support and specific industry expertise concentrated on Food & Beverage in the US. The Siemens Food & Beverage Vertical Market Management (F&B VMM) team offers industry specific business solutions without silos or borders. We work to establish long term relationships in order to create references and develop strategic partnerships with industry-leading customers. F&B customers want to do business with partners who understand their current and future needs and have the ability to cross regional and functional boundaries to provide support for their key initiatives. Customers want partners who provide superior, creative solutions to difficult challenges. Siemens F&B VMM fulfills this objective.

SPX Flow Technology SPX’s Flow Technology segment designs, manufactures and markets products used to process, blend, dry, meter, and transport fluids. Recognized for its leading brands and turnkey systems capability, the Flow Technology segment has global operations which serve the Food & Beverage, Power & Energy and Industrial markets. We offer a complete line of sanitary valves, pumps, scrape heat exchangers, homogenizers, mixers, dryers and evaporators for today’s modern processing facilities. It’s hard to find a more comprehensive portfolio of processing equipment anywhere else. Many of our designs incorporate patented features and our research and development efforts continue to produce ground-breaking technologies. Food and beverage manufacturing has never been more challenging. Margins are squeeze and food safety is paramount. Consumer demands for new products make formulation changes a regular occurrence. To meet these challenges head on, you need a partner with a deep understanding of process engineering and a broad portfolio of equipment. Explore the endless solutions that SPX Flow Technology has to offer. You’re sure to find answers that will improve plant performance, increase profitability and enhance the value of your brand.

• Ability to enable F&B customer’s strategic initiatives such as sustainability, speed-to-market, quality, and flexibility. • Expert focus on solutions for strategic F&B industry challenges • Dedicated industry expertise in customer categories and segments • Global experience and world-wide support networks • Strategic management of complex relationships among customers, OEM supplier, solution partners, channel partners, and Siemens.

Contact: Siemens Industry Inc 1201 Sumneytown Pike Spring House, PA 19477 (423) 747-5850 www.usa.siemens.com/foodbev [email protected]

Contact: SPX Flow Technology 611 Sugar Creek Road Delavan, WI 53115 Phone: 262-728-1900 or 800-252-5200 Fax: 262-728-4904 Email: [email protected] www.spx.com

See us at PROCESS EXPO Chicago booth #868

See us at PROCESS EXPO Chicago booth #1002

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Top Line Process Equipment Always Giving You Top of the Line Service and Quality! Visit us at The Process Expo: Booth 413 Top Line Process Equipment Company continues to be a leading supplier of quality hygienic stainless steel process equipment for 50 years. Our commitment to fine craftsmanship, high quality, unequaled service, and competitive pricing has led to our company’s successive years of growth which has placed us among the leaders in our industries. Top Line services the food, dairy, beverage, cosmetics, pharmaceutical, biotechnology and electronics industries. EXTENSIVE PRODUCT LINE As experts in the hygienic processing industry we are always upgrading and expanding our product line to bring you the highest quality components and the latest innovations at the most competitive pricing. Our product line includes: • Hygienic Stainless Steel Valves (Flow Control, Butterfly, Ball, Diaphragm, Sample, Divert, Plug, Ball Check, Disk Check) • Flow Control Valve Clusters (Mix Proof, Shut Off and Divert) • Hygienic Stainless Steel Pumps (Centrifugal, Rotary Lobe, Magnetic Drive) • Hygienic Stainless Steel Tubing and Tube Hangers • Sanitary Stainless Steel Fittings * Pump Dolly & Pump Carts • Sanitary Gaskets • Hygienic Stainless Steel Gauges • Custom-made Specialties • Accessory Items and Component Parts TOP OF THE LINE SERVICE Our extensive product line is the most complete in the industry and we maintain warehouse facilities for the most responsive service and fast turnaround. We understand your requirements for equipment and we can meet your most stringent specifications. Our products are in compliance with industry organizations including the FDA, USDA, ASME BPE and 3A sanitary standards. For top of the line products and service, there’s only one name to remember, Top Line. For more information about our products, please visit our website at www.toplineonline.com or call us today.

Contact: Top Line Process Equipment Company John Auteri- General Sales Manager 21 Valley Hunt Drive * Lewis Run, PA 16738 Phone-814-362-4626 • Toll Free- 800-458-6095 Fax- 814-362-4453 www.toplineonline.com • [email protected] Visit us at PROCESS EXPO Chicago booth #413

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Urschel Laboratories, Inc. NEW E TRANSLICER® CUTTER DEFINES EFFICIENT, ENGINEERED EXCELLENCE Engineered to produce continuous precision slices with extensive detail given to key elements throughout the machine, the new E TranSlicer® Cutter joins the production-proven TranSlicer series in the Urschel line-up. “In 2010, we celebrated the company’s 100-year anniversary. On the heels of that, we are proud to announce the introduction of our latest TranSlicer. Building on a tradition of Urschel quality, this new machine demonstrates the company’s engineering-driven spirit which has been key to the company’s ongoing success all these years,” stated Tim O’Brien, vice president of sales at Urschel. The E TranSlicer uses the same 20” wheel and delivers the same types of cuts as its predecessor, the TranSlicer 2000 Cutter. The machine also accepts the same size infeed of 4” (102 mm) diameter firm products, more compressible products up to 6” (152 mm) diameter, and offers the same productionproven operating principle. In addition, the E TranSlicer provides a newly designed cutting wheel mount/holder assembly that simplifies cutting wheel changeovers. Hinged/sliding access panels offer full access to all key areas of the machine. To further ease washdowns, surfaces are sloped. Sanitary design ensures that all mechanical components are separated from the food zone. Electrical cables are slightly raised off of the machine frame to simplify washdowns and alleviate trapped food particulates. The E TranSlicer is available with across-the-line start or with a variable frequency drive.

Contact: To learn more about the E TranSlicer, please contact: Urschel Laboratories, Inc. E-mail: [email protected] Phone: (219) 464-4811 www.urschel.com PO Box 2200, 2503 Calumet Avenue Valparaiso, IN 46384-2200 U.S.A. Visit us at PROCESS EXPO Chicago booth #1412

2011 PROCESS EXPO SHOW Previews Special Advertising Section

VNE Corporation

Woodard & Curran

VNE Corporation is a leading manufacturer of stainless steel fittings, valves, and specialty related products, both for sanitary and industrial applications. VNE also offers stainless steel sanitary and industrial tubing. VNE Corporation is dedicated to continuing the traditions that have made its parent company a success: exceptional quality, advanced manufacturing technology, great customer service, and intensive research to develop new products directly related to customer needs. Our reputation is built on these principles.

Founded in 1980 in Janesville WI, VNE a member of the Neumo Ehrenberg Group consists of 26 companies in 16 countries around the world. The Neumo - Ehrenberg Group is a privately owned, diversified multi-national organization consisting of 26 companies in North America, Europe, and Asia. With our three leading companies, Neumo, VNE and EGMO, our group has developed a worldwide distribution channel partner network, including large stock depots, supporting major biopharmaceutical multinational accounts. The Neumo - Ehrenberg synergy and strategy toward the Biopharmaceutical, API, Personal Care, Food and Dairy sectors provide customers with innovation, higher quality products and manufacturing efficiencies. Through our groups volunteer participation in leading industry organizations, standards and specification development as well as educational seminars we are actively helping to shape the future for a cleaner, safer and more productive workplace in the industries we are serving.

Woodard & Curran delivers sustainable designs and optimum performance to Food and Beverage industry clients. We have designed, permitted, and installed some of the most efficient manufacturing facilities in the world for beverage, dairy, protein, snack food, dressings and dips, and sauce manufacturers. The bundle of services Woodard & Curran offers is extensive. We provide the complete design, installation, startup, and environmental health and safety support needed for process lines and associated utility infrastructure, including: • Packaging equipment specification; • Bottle manufacturing design; • Manufacturing line layout design; • Water and wastewater; • Sustainability and product environmental footprinting; • Energy management; • Environmental compliance; • Compressed air; • Refrigeration and chilled water; and • Water resource management and hydrogeology. As an integrated science and engineering company, our clients have access to expertise a wide array of disciplines such as information management, automation (instrumentation and controls), training, site-civil permitting and design, and contract operations. We build successful partnerships and apply proven approaches to lean manufacturing. We deliver value by integrating best-in-class components that lower maintenance costs, decrease downtime, and increase efficiency. We measure success in line efficiency, waste minimization, streamlined handling, and plant flexibility with regard to both products and line balance. Woodard & Curran is a 600-person, integrated engineering, science, and operations company. Privately held and steadily growing, we serve public and private clients locally and nationwide.

Contact: VNE Corporation 1149 Barberry Drive PO Box 1698 Janesville, WI 53547 608-756-4930 800-356-1111 Fax: 608-756-3643 www.vnestainless.com Visit us at PROCESS EXPO Chicago booth #3603

Contact: Woodard & Curran Eric Carlson, PE Senior Vice President 41 Hutchins Drive, Portland, ME 04102 800.426.4262 [email protected] www.woodardcurran.com See us at PROCESS EXPO Chicago booth #2237

VNE serves the dairy, food processing, beverage, pharmaceutical,cosmetics, chemical, water treatment, and many other industries. All orders - large or small - receive our immediate attention and carry the quality, name, and reputation of VNE.

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Pump Solutions Group (PSG™)

Problem Solving Pumps for Food Applications Pump Solutions Group (PSG™) delivers cohesion, synergies and relevant value to our customers with superior products, world-class operations and a tireless commitment to excellence. PSG offers you a broad array of quality and innovative pump technologies that you’ve come to expect from premiere pump brands like Wilden, Blackmer, Mouvex, Neptune, Almatec, EnviroGear and Griswold. At the upcoming Process Expo in Chicago, PSG will have two of its worldclass brands prominently featured in Booth 3608. At the show, Wilden will be featuring its Pro-Flo X™ HS (Hygienic Series) stainless steel pumps, while Mouvex will have its full line of eccentric disc pumps on display for attendees.

Wilden Pro-Flo X™ HS (Hygienic Series) pumps offer the versatility, safety and capability needed to efficiently pump the full range of viscosities, solids and shear-sensitive products that are used in food and beverage processing. These pumps have been specifically designed to meet strict guidelines established for sanitary process applications such as, FDA, 3A, and EHEDG. HS pumps incorporate shear sensitive operation, flow-through design, large solids passage, maximum efficiency, and CIP (clean in place) features to insure process success. HS pumps also come equipped with the patent-

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pending Pro-Flo X™ air distribution system including the Efficiency Management System™ for increased energy efficiency. Wilden will also be showcasing its Saniflo™ Vacuum-Controlled (VC) Series Metal Pumps, which are designed to efficiently and sanitarily handle a wide array of very large solids because they do not employ an air motor, but utilize a vacuum generator that draws the product into the wetted housing. For more information on Wilden pumps, please visit www.wildenpump.com.

Mouvex SLC-Series eccentric disc pumps are the only nonpulsating positive displacement pumps for the sanitary industry that have no mechanical seals. The SLC is unique because it’s truly a positive and constant flow pump, independent of process and system conditions such as product viscosity, system back pressure, temperature and even wear. Because of the “no slip” properties, it dry primes, is able to produce negative suction lift and line strip. Mouvex C-Series and Micro C-Series eccentric disc pumps help to eliminate leakage and costly product loss of high-value ingredients due to a unique oscillating pump chamber that delivers high-volume efficiency while gently handling shear-sensitive ingredients. C-Series and Micro C-Series pumps are constructed with a seal-less design, capable of dry priming, line stripping and tank clearing for use in multi-purpose pumping applications, offering the food industry the most reliable prevention against leaks and product loss. In addition, all three of these Mouvex eccentric disc pumps are designed to meet the highest sanitary requirements, carrying the EHEDG and 3A symbols, and are designed for CIP cleaning. For more information on Mouvex pumps, please visit www.mouvex.com.

Contact: Wallace Wittkoff Hygienic Director, Americas Pump Solutions Group (PSG™) 1100 W. 31 St., Suite 120, Downers Grove, IL 60515 USA PH: 502-905-9169 Email: [email protected] Web: www.pumpsg.com See us at PROCESS EXPO Chicago booth #3608

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141

AD INDEX

April 22-25, 2012 Sanibel Harbour Marriott COMPANY

PHONE NUMBER

A&B Process Systems

PAGE

•

COMPANY

Fort Myers, FL PHONE NUMBER

71

JBT FoodTech

800-477-1214

63

K Tron

800-466-2369

53

Key Technology

Air Blast, Inc.

626-576-0144

59

Lee Industries

814-342-0461

57

Allpax

888-893-9277

22

Lubriplate Lubricants Co.

800-733-4755

18

AAF Innternational Admix Inc.

www.jbtfoodtech.com

11

www.ktroncan.com

75

509-529-2161

88

AM King Construction

704-365-3160

44

Ludeca Inc.

305-591-8935

42

Amerivap Systems

404-350-0239

82

Marchant Schmidt Inc.

920-921-4760

14-17

Anderson Instrument Co

800-833-0081

57

Material Transfer & Storage

Anritsu Industrial Solutions USA Inc.

847-419-XRAY

30

MEPACO

800-528-7411

62

800-682-4594

93

www.theaustin.com/foodgroup

6

www.bdbiosciences.com

24

Arizona Instrument LLC Ashworth Austin Company BD Biosciences Beckoff Bel-Ray

www.beckoff.com/stainless-steel-panel 73

800-836-7068

50

920-356-9900

96

Mettler-Toledo Safeline

800-221-2624

111

Midwestern Industries, Inc.

877-4-SIZING

Mobil Industrial Lubricants

www.mobilindustrial.com

27 28-29

Mouvex

www.mouvex.com

49

Moyno

877-4UMOYNO

106

Mueller

800-MUELLER

74

www.-bel-ray.com

5

BETE Fog Nozzles

413-772-0846

23

Netzsch Pumps North America, LLC

610-363-8010

51

Bimba

800-44-BIMBA

12

Nord Drive Systems

www.nord.com

40-41

Breddo Likwifier Bühler

800-669-4092

IBC

63-847-9900

95

Omega Engineering Inc. Perfex

888-82-OMEGA

2

800-848-8483

91

Bunting Magnetics Co.

800-835-2526

48

Power Engineers

888-687-8811

83

Burns & McDonnell

816-822-3831

69

Quickdraft

855-VENTURI

84

55

Reid Supply Company

800-253-0421

45

Butterworth Clarion White Oils Clayton Industries Coastline Equipment, Co.

281-821-7300 855-MY-CLARION 800-423-4585

38-39

Reiser

32

Ross, Charles & Son Company

781-821-1290

21

800-243-ROSS

35, 37

360-734-8509

46

SEW Eurodrive

CPM Wolverine Proctor

215-443-5200

56

Schenk Accurate

Demaco

321-952-6600

72

Siemens

800-543-3634

61

Smith Cooper International

800-766-0076

76

Dorner

800-397-8664

36

Sonic Air Systems

800-82-SONIC

31

Douglas Machine

800-331-6870

52

Spraying Systems Co.

Dur-A-Flex

800-253-3539

110

Eriez Magnetics

888-300-ERIEZ

20

Summit Industrial Products

800-749-5823

63

Evergreen Packaging

319-399-3200

43

T.D. Sawvel

877-488-1816

58

Flexicon Coporation

888-353-9426

BC

Tel-Tru Manufacturing Co.

800-232-5335

59

Fristam Pumps

800-841-5001

7

Terlet USA

800-965-6065

10

877-GAMAJET

53

Top Line Process Equipment

800-458-6095

55

877-844-7226

33

Triple S Dynamics, Inc.

877-542-8010

9

www.grecon.com

62

Ultrachem Inc.

302-325-9880

47

Urschel Laboratories, Inc.

Donaldson Company, Inc.

Gamajet Graco Gre-Con

SPX

Hapman

877-314-0733

78

Harpak

800-813-6644

101

Heat & Control

800-227-5980

34

VNE

I. J. White Systems

631-293-2211

54

Wilden

www.inpro-seal.com

4

Inpro/Seal Ingersoll Rand Inline Ball Valve JAX

www.ingersollrandproducts.com 103 800-568-8998

86

800-782-8850

51

Vac-U-Max

Wire Belt Company of America Woodward & Curran Zeppelin Systems

www.seweurodrive.com

98

800-394-2941

60

www.usa.siemens.com/foodbev

81

800-95-SPRAY

October 2011 | Food Engineering | www.foodengineeringmag.com

26, 94

www.spx.com

IFC

219-464-4811

1

800-822-8629

97

www.vnestainless.com

47

909-422-1730

108

603-644-2500

105

www.woodwardcurran.com/fe

77

813-920-7434

85

Further information on these companies can be found in the 2010-2011 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.

142

PAGE

888-254-2789

ENGINEERING R&D Kevin T. Higgins, Senior Editor

GE salmon swim upstream

`

Genetically engineered grains are mainstream, but gene splicing in livestock remains experimental. A Boston area biotechnology firm hopes to change that. Researchers Garth L. Fletcher and Choy L. Hew of Canada’s Memorial University began their transgenic fish experiments in 1982, eventually mastering microinjection of antifreeze protein genes from the ocean pout into fertilized Atlantic salmon eggs to enable caged salmon to survive the winter waters off the Newfoundland coast. Next, they mastered integration of the antifreeze protein with the growth hormone DNA of the giant Chinook, king of the salmon species. The technology was licensed to a Waltham, MA-based biotech firm, which spun off Aqua Bounty Technologies Inc. in partnership with the scientists. The transgenic salmon line was established in 1992. Establishment of genetically engineered (GE) feedstock was the fast-track part. Developers initiated discussions with FDA in 1993 to determine an appropriate approval process. After floundering in uncharted regulatory waters, the first study to support a new animal drug application was submitted in 2001. By then, various public interest and environmental groups had mobilized in opposition. By the time the FDA’s Veterinary Medicine Advisory Committee ruled last year GE salmon was

` Ronald L. Stotish, president and CEO, Aqua Bounty Technologies Inc., Waltham, MA. Source: Aqua Bounty Technologies Inc.

safe to eat and posed no environmental threat, the Alaska Congressional caucus and others began efforts to block approval. Leading Aqua Bounty’s counteroffensive is Ronald L. Stotish. He joined the firm in 2006, serving as vice president for regulatory affairs, then senior vice president-R&D and president and CEO. A biochemist and molecular biologist with advanced degrees from Rutgers University and a bachelor’s degree from Penn State, Stotish describes himself as “a product of the pharmaceutical industry” and an expert in animal health. FE: How does GE salmon differ from wild Atlantic salmon? Stotish: There’s nothing special about our fish. It has

the exact same amino acid sequence as the Atlantic salmon’s growth hormone. Whereas conventional salmon exhibit a delayed initial growth pattern, however, this salmon grows more or less like a trout. And it should be noted that, outside a wild source in waters outside of Iceland, today’s Atlantic salmon are a cultivated species that are placed in sea cages for grow out. By allowing the fish to produce growth hormone with the on/off switch from the ocean pout’s antifreeze gene, early growth occurs. You can’t achieve the growth rates that we achieve by simply putting the fish in warmer water. You could achieve these growth benefits with classic methods, but it would take 50 years, whereas we achieve them in one generation. FE: With these salmon reaching market weight in half the time, would you expect them to be priced lower?

Stotish: There is the potential for lower-cost salmon,

but the real benefit is that, because they grow at a more predictable and rapid rate, it allows land-based cultivation. Currently, young fish are put out to sea after years of early growth in pens. Aquaculture in a pond or tank isn’t done because three to five years are needed, and the utility costs alone would be prohibitive. These salmon would allow land-based production near consumption centers, eliminating the carbon footprint associated with transport, which is significant. FE: What do you say to advocates of traditional fisheries? Stotish: It’s not a myth; it’s a fact: The world wild-

caught fisheries are stressed. We’re approaching 7 billion global population, and we could reach 9 billion in 20 years. Annual growth of 10 percent in aquaculture has been going on for 20 years, and the US is way behind. A lot of technology and American innovation have gone into transgenic fish. Other nations are trying to

www.foodengineeringmag.com | Food Engineering | October 2011

143

ENGINEERING R&D

` Growth rates are accelerated significantly in genetically engineered salmon, as illustrated by these siblings, the smaller of which did not receive the transgenic growth gene. Source: Aqua Bounty Technologies Inc.

catch up on our research, notably China, which has a huge effort in this area. At least 18 other GE livestock projects are waiting until the outcome of our petition. At the end of the day, we may still emerge as the world leaders, but there’s the real danger the US will remain importers of seafood developed with our technology. FE: If commercial production is approved, where do you anticipate salmon aquaculture will occur? Stotish: South Dakota is very interest-

ed in hosting grow-out operations, and there is interest throughout the Great Lakes region, particularly Ohio and Illinois. You just need a suitable supply of water to set up a facility that can produce 1,000 tons of salmon a year. In 2009, 200,000 tons of salmon were imported, so it would only take 200 facilities to make us self-sustaining. FE: A number of veterinary doctors and scientists have become outspoken supporters of transgenic salmon, including William Muir, whose Trojan gene hypothesis is the basis of objections based on possible extinction of wild salmon populations. Has that helped allay concerns? Stotish: Dr. Muir, a professor at Purdue

University and an expert in aquaculture breeding and genetics, has pointed out that the hypothesis is not valid in respect 144

to our salmon, yet opponents c o n t i n u e to raise that issue. We had hoped the approval would be a fair and respectful exchange of ideas. Unfortunately, some organizations have taken great liberty with the truth. That has been a great disappointment, but we have to take the high road.

FE: Eight senators subsequently signed a letter to FDA, urging Commissioner Margaret Hamburg to cease the approval process. Might their effort succeed? Stotish: The letter signers are pretty

FE: This summer, pushback came from Congress, notably from the Alaska caucus. Are they primarily protecting Chinook commercial fishing interests? Stotish: If they had taken on the GE

and haven’t gotten feedback from anyone. The environmental assessment has been prepared. It must be published in the Federal Register, at which point a 90-day comment period would begin before we can proceed. Product safety and effectiveness already have been established, so it makes no sense not to publish the environmental assessment. We have provided all the requested data, everything is on the record, and unless it goes forward, the process has no credibility. Already, there’s been a chilling effect on similar new technology, and further delays would scare off potential investors. But there’s still a sense of fair play in America, and we’ve been gratified by the amount of support we have gotten.

salmon with an economic argument, we could have engaged them. Chinook is a high-quality, seasonal fish that is very different from Atlantic salmon. It’s doubtful GE salmon would impact market prices for Chinook. Instead, the rhetoric has been inflammatory. FE: A House amendment to the appropriations bill forbids FDA to make any expenditures reviewing GE salmon. S t o t i s h : Even if the amendment

were passed by the Senate, which is extremely doubtful, FDA review has already been completed. The House action was an exercise in showmanship and shenanigans. The vote occurred June 20, the day the White House hosted a barbecue for Congress. Only eight House members reconvened at the Capitol at 8 p.m. Despite the lack of a quorum, a voice vote was taken on the floor, and the amendment was passed. It does not represent a sense of the House, and 38 organizations wrote letters, condemning it as a sham. Other people also have spoken up to Congressional leaders and FDA, telling them this approval is not something to be turned into a political sham.

October 2011 | Food Engineering | www.foodengineeringmag.com

much the people who oppose technology. W hen challenged, they say, “I’m personally uncomfortable with transgenic livestock.” That’s fine, but that shouldn’t be the basis of regulatory policy. FE: What’s the next step in the process? Stotish: We’re sort of in purgatory

FE: Genetically modified corn, soybeans and other seeds dominate some crops. Why has GE flora been accepted so much more easily than GE fauna? Stotish: The review process involving

USDA and EPA for plants is more clearly defined. Nonetheless, we support the FDA scientific process. The fact that it is rigorous means people will have confidence that the GE animals that get through it will be safe. The irony is that it’s so much easier to move DNA around in animals than in plants. Whether animals, plants or medicines are created with recombinant DNA, it’s all part and parcel of the same technology. ❖

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