Food Engineering September 2011

SPECIAL REPORT: TIME TO RESHUFFLE PACKAGING PRIORITIES, FOCUS ON PERFORMANCE September 2011

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THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT

The World’s Top 100 Food & Beverage Companies

Global Power Shifts

ALSO THIS MONTH ` PERFORMANCE TOOLS FOR

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FEATURES COVER STORY

62

The World’s Top 100 Food & Beverage Companies Growth in emerging markets is driving activity, despite the need for manufacturers to tackle economic challenges, cut costs, ensure operational efficiency and decrease environmental impact.

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Performance Tools for Continuous Improvement Altering processes and procedures requires human involvement, but that doesn’t preclude technical support for continuous improvement efforts.

87

64

Packaging Trends Survey Speed always is a priority in packaging operations, but market realities are elevating other considerations for food and beverage professionals.

95

20

Tech Update: Robotics After they’ve proved their worth in secondary packaging and grunt applications, robots are slowly making inroads for jobs closer to the process.

DEPARTMENTS 8

Editor’s Note

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Calendar of Events

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Manufacturing News Cargill facility adds waste-to-energy capacity.

19

Food Packaging Rotating label increases communication at point of purchase.

25

Food Safety Fear mongering in the media

136

31

Focus on Metal Detection, X-ray and Mixing & Blending Equipment

108 Connect with FE on Facebook

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Join FE’s Group on LinkedIn Food Engineering Magazine

Field Reports Spice processor increases quality with metal detection.

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Technology Sourcebook

110

PACK EXPO Preview

128

Classified Advertising

135

Engineering R&D New solutions for slaughter and animal welfare

www.foodengineeringmag.com | Food Engineering | September 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 FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT: Tel. 847-763-9534 or Fax 847-763-9538 or e-mail [email protected]

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FOOD ENGINEERING Volume 83, Issue 9 (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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EDITOR’S NOTE

The times they are still a-changin’

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

n my editor ’s note last month, I addressed the many changes our industry is experiencing in food safety and sanitary design as well as staffing issues concerning up-and-coming manufacturing management styles. In this edition of Food Engineering, we cover many more changes in the food and beverage manufacturing arena, particularly with our annual cover story on the World’s Top 100 Food and Beverage Companies. In some cases, the changes are astounding. As this month’s cover states, a major global power shift is underway. The current economic climate is reshaping the face of our industry like never before, with many of the largest food and beverage companies obtaining more than half of their income from outside their home markets. In addition, the Top 100 list now includes newcomers from Brazil, China and Japan. According to our Top 100 report, CEOs from leading food and beverage manufacturing companies believe finding the right talent to lead our industry will be a challenge.

They say talent that is truly global in experience and thinking is needed to lead the food industry in the coming decades. According to a recent NPR report, US policymakers want entrepreneurs to create new jobs to boost the economy. The problem is that many foreign-born entrepreneurs who want to come to the US are held up by immigration laws. Innovation and economic development experts are now advocating passage of legislation called the Startup Visa Act, states NPR News. These experts say it is time for the US to put aside political battles and get these entrepreneurs here to create hitech jobs that will boost our economy. Two things are true. One is the obvious need to stimulate the economy and keep American business on top. The other is the not-so-obvious need to open our doors to foreign entrepreneurs to help rebuild the American economy and provide global thought leaders to boost our talent pool. The times are changing, and now is the time to act. Tumultuous times demand outside the box remedies. ❖

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

September 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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`NEWS PLANT OPENINGS & EXPANSIONS Agro Farma, maker of Chobani Greek-style yogurt, will expand its operations in New Berlin, NY. The $90 million project is expected to add about 450 jobs to its already existing roster of nearly 400 employees. The Dannon Company Inc. plans to expand its 400,000-sq.-ft. Minster, OH plant to increase production capacity. The $88 million expansion is expected to add 100 new jobs over the next three years. The facility currently employs more than 400 workers.

Turtle Island Foods, maker of Tofurky and other soy-based products, is building a 33,000-sq.-ft., $10 million production facility in Hood River, OR. The riverfront facility will employ as many 100 people and is expected to open in 2012. The 31-year-old company expects a 25 percent sales growth in 2011. Michter’s Distillery LLC will build a small production facility in the historical Fort Nelson Building in Louisville, KY. The facility will be open to the public with educational tours and tastings. Michter’s production includes very small batch bourbons, single-barrel bourbon and ryes and unblended American whiskey. Golden Boy, a Canadian company, is opening a peanut butter plant in Troy, AL. The new plant will be staffed with 65 people in 2012, and is expected to increase to 130 within two years.

Cargill facility adds waste-to-energy capacity

C

argill’s beef processing facility located in High River, Alberta, Canada already recovers methane to produce 25,000 lbs. of steam per hour, but the company w i l l increase its capacity to generate energy to meet 80 percent of the plant’s needs in 2012 with a new waste-to-energy project. The C$36 million joint project is cosponsored by the government of Canada as part of its initiative to help meat processors reduce their environmental impact. The Canadian government will contribute approximately C$10 million to the effort. This public-private collaboration for creating energy from waste that would otherwise be sent to a landfill is said to be the first of its type in North America and the largest single waste-to-energy project Cargill has undertaken on the continent. When in operation, the fluidized bed boiler project is expected to eliminate 21,000 metric tons of fossil fuel emissions annually, in addition to mitigating the facility’s electrical energy requirements by producing 1.4 megawatts of power. Combined with the facility’s existing methane gas capture that prevents release of this greenhouse gas into the atmosphere, and its subsequent use as fuel for the plant, 75 to 80 percent of the facility’s energy needs will come from renewable sources. In addition, waste load to local landfill sites will be decreased, which is a benefit to the community.

` Cargill will locate its new waste-toenergy facility (red rectangle) on the east side of the plant. It is expected to be operational in May 2012. Source: Cargill.

“Using existing technology, we will install specialized equipment that will make our High River beef processing facility the most sustainable and environmentally friendly beef processing facility in the world,” says John Keating, Cargill Beef president. “Recognizing the environmental, agricultural and community value and benefits of this project is a tribute to the Canadian government and its visionary approach to working with business to find mutually beneficial solutions to long-term challenges.” The High River beef processing facility employs approximately 2,000 people who harvest 4,000 beef cattle daily, representing C$1 billion in annual cattle purchases and totaling one-third of Canada’s processed beef volume. The facility is ISO 14001 certified, i.e., the plant has an environmental management system focused on a systematic and measurable approach to improving its environmental impact.

www.foodengineeringmag.com | Food Engineering | September 2011

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MANUFACTURING

`NEWS

Kraft Foods to create two independent companies Kraft Foods board of directors intends to create two independent companies: a

high-growth, global snacks business with estimated revenue of about $32 billion and

a high-margin North American grocery business with estimated revenue of about $16 billion. Expected to be completed in about 12 months, these companies will be created through a tax-free, spin-off of the North American grocery business. “We have built two strong, but distinct portfolios,” says Kraft Foods Chairman and CEO Irene Rosenfeld. “Our strategic actions have put us in a position to create two great companies, each with the leadership, resources and strong market positions to realize their full potential.” The company believes creating two public companies will offer a number of opportunities: • Each business will focus on its own distinct strategic priorities, with financial targets that best fit its own markets and opportunities. • Each will be able to allocate resources and deploy capital in a manner consistent with strategic priorities. • Investors will be able to value the two companies based on their particular operational and financial characteristics and invest accordingly. Global snacks will consist of the current Kraft Foods Europe and developing markets units as well as the North American snacks and confectionery business. The North American grocery business will consist of the current US beverages, cheese, convenient meals and grocery segments and the nonsnack categories in Canada and food service. The grocery business will have a highly competitive retail presence, cost leadership and a continued commitment to innovation and marketing excellence, says Kraft. 14

September 2011 | Food Engineering | www.foodengineeringmag.com

REGULATORY WATCH DeLauro says food safety agencies need more funding Rep. Rosa DeLauro (D-CT) seized on Cargill’s early August recall of 36 million pounds of ground turkey to renew her call for increased funding to federal agencies that inspect the food supply. She issued a statement shortly after the company announced the recall of product from its Meat Solutions Corporation plant in Springdale, AR because of possible Salmonella contamination. “This massive recall is yet another example of how critical it is to fully fund and support the agencies that are responsible for protecting our food supply,” DeLauro said. “It has been over four months since the first illness was identified and yet we just identified the facility and we still do not know definitively where the contamination occurred.” DeLauro was critical of House Republicans, whom she said had slashed funding for the FDA and USDA, the two principal agencies for monitoring food safety. “We must invest in our public health infrastructure in order to identify outbreaks earlier, better protect the public health and empower our food safety agencies to enable faster, accurate traceback,” DeLauro said. “These agencies need the funding to fulfill their mission of protecting American consumers.”

ulated industry, the discussion draft would impose new and intrusive government mandates on dairy markets at the cost of a growing dairy export business and the jobs that have come with it,” Tipton says. She adds the program would adversely affect every dairy producer and pro-

cessor in the country, and would impose limits on milk production, at a time when world food demand is rising. “The solution is not to get government more involved in our markets, but to let our industry grow and produce jobs,” Tipton says.

Wrong direction for dairy? Dairy processors are taking strong exception to legislation being drafted by Rep. Collin Peterson (D-MN), ranking member of the House Agriculture Committee. The legislation would establish the Dairy Market Stabilization Program, designed to support the price of milk. Connie Tipton, president and CEO of the International Dairy Foods Association, says the measure would take the dairy industry in the wrong direction. “Instead of encouraging job growth and reducing regulation on an already over-regwww.foodengineeringmag.com | Food Engineering | September 2011

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MANUFACTURING

`NEWS INDUSTRY & PEOPLE PMMI named five inductees to the Packaging Hall of Fame. The Class of 2011 includes: Victor Del Rosso , Hi-Speed Checkweigher (retired); Lawrence C. Dull , MS, CPP, Pack-

aging Knowledge Group; Arthur Gustafson , Algus Packaging; Thomas L. Schneider , CPP, Industrial & Shippers Supply; and M.H. “Pete” Wallace , SWF Machinery (retired).

Daniel Myers joined Kraft Foods as executive vice president, supply chain, and will lead the functional supply chain groups including procurement, manufacturing, engineering and customer service and logistics.

Grocery Manufacturers Association appointed George E. Dunaif as its vice president of food safety and technical services.

William R. Nowak joined TranSystems to lead the industrial engineering/ time study area for the company’s management and supply chain consulting group. The International Refrigerated Transportation Association (IRTA) elected new officers and directors. John Williamson, chairman of E.L Johnson’s

NE

W

Sons and Mowatt in Illford, Essex, UK, was elected 2011-2012 chairman of IRTA. Chris Mnichowski (Cold Train Intermodal, Inc., Overland, KS) was elected vice chairman, and M. K. Wong (OOCL, San Ramon, CA) was elected treasurer. Newly elected directors include: Peter Hurme (Cargo Business News, Seattle, WA); Keith Mowery (United States Cold Storage, Voorhees, NJ); Debbie McDowell (ICS Logistics, Jacksonville, FL); and Matt Zerfoss (Pictsweet Foods, Bells, TN). The industrial automation group of Advantech and Industrial Video and Control announced their partnership to provide state-of-the-art video surveillance solutions.

Garlock Sealing Technologies, LLC signed an agreement to acquire the ONEUP Pump Diaphragm business from W. L. Gore & Associates, Inc.

Snyder’s-Lance, Inc. acquired all of the issued and outstanding shares of George Greer Company, Inc., a snack food distributor serving Rhode Island, eastern Massachusetts and New Hampshire markets.

16

September 2011 | Food Engineering | www.foodengineeringmag.com

Buckhorn Inc., a provider of reusable plastic packaging systems, acquired tooling assets and intellectual property from Material Improvements L.P. for a new reusable plastic container used in producing, shipping, storing and processing bulk natural cheese.

T.G.I. Friday’s secured Brand2 Squared Licensing, a division of Peppercom, to seek new licensees and create food and beverage consumer products that are like Friday’s menu items.

Spectris plc of Surrey, England signed an agreement to acquire Stamford, CTbased Omega Engineering. Both companies manufacture instrumentation and control systems.

Sunsweet Growers Inc. acquired Function Drinks, a southern California company known for its line of dietary supplement beverages.

Leprino Foods opened a plant in Singapore to make cheese and other dairy products for the Asia-Pacific region.

OpenGate Capital, an investment firm, plans to buy a Wisconsin dairy processing facility from Dean Foods.

Archer Daniels Midland signed an agreement to purchase a majority share of Elstar Oils SA, a Polish vegetable oil producer. Pilgrim’s Pride Corporation announced plans to close its chicken processing plant in Dallas, TX. The International Association for Food Protection (IAFP) honored Rapid Recall Exchange with the Food Safety Innovation Award at the 2011 IAFP Annual Meeting.

Sara Lee will sell its refrigerated dough business to Ralcorp for approximately $545 million. Cargill has made a binding offer to acquire Provimi, the global animal nutrition company, for an enterprise value of 1.5 billion from Permira funds, the private equity firm which owns Provimi.

Magnet Applications, a subsidiary of Bunting Magnetics Company, announced the addition of Pete Lipetzky as its new general manager for the DuBois, Pennsylvania facility.

www.foodengineeringmag.com | Food Engineering | September 2011

17

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

Give it a twist

`

Rotating label increases communication at the point of purchase and helps differentiate food products from the competition.

O

atmeal has a right to preen, given the distinctive, round canister that sets it apart from other supermarket products. But oatmeal may soon be outdone in the frozen food locker, where canisters sporting peek-a-boo labels that can simulate an interactive experience are starting to appear. Koch Foods debuted breaded chicken chunks in a canister with a rotating outer label earlier this year under the Kirkwood label in Aldi food stores. The suburban Chicago-based poultry processor developed the spin label package in conjunction with equipment suppliers Huhtamaki Systems and Accraply Trine and label-maker MPI Label Systems. Following the successful Aldi trial, Koch officials expect a broader rollout later this year. Koch merchandisers worked “for the better part of a year” with vendors to develop an integrated packaging line to form the paperboard canisters, fill them with chicken and enrobing sauce, and apply a second label with a clear panel that exposes the container’s inner printed surface, according to Ron Leskiw, lead sales-retail. By rotating the outer label, recipes and serving suggestions are exposed in the panel. Leskiw estimates the spin label provides an additional 60

` Kirkwood, a private label of Aldi supermarkets, was the first frozen food packaged with a spin label that delivers more information, better protection and a point of distinction. Source: Huhtamaki Systems.

percent of label space. It also sets the value-added product apart from competing products in gusseted bags and provides superior protection. “If you want to be noticed and you’re toe to toe with Tyson and Pilgrim, you have to take a bit of a gamble,” says Leskiw. “Retail buyers like to see thinking outside the box, and a number of them are saying, ‘That’s really a different idea.’” Dietary supplements, beverages and other products in cylindrical packages have licensed the spin label concept from Spinformation Company, Turlock, CA, in the last decade, but most of those containers were blowmolded plastic or spiral-wound tubes, notes Kristi Sics, product manager-systems at DeSoto, KS-based Huhtamaki Systems. “Paperboard behaves quite differently,” she points out, and the machine builder spent several months modifying existing canisters that ship flat and are shaped round at the point of filling. The challenge was ensuring the outer label stays on and spins freely on a paperboard surface. Tack between the two labels secures them until someone “initiates the spin,” Sics adds. Earlier versions of the spin label were pressure sensitive, and that added about eight cents to package cost, notes inventor Stephen Key, developer of the rotating label. The oriented polypropylene label on Koch’s paperboard cylinder leverages roll-fed technology to trim costs by more than half. That’s still a high premium for food packaging, which is why Koch management “thinks of it more as a marketing cost than a cap ex,” says Leskiw. The switch to lower-cost roll-fed technology was driven by manufacturers with high-speed beverage lines, says Key. The Koch application adds another layer of complexity, given the cold and moisture that the containers must withstand and still deliver a rotating outer label. The Kirkwood chicken is breaded, and the canister does a better job protecting the breading than a bag, Leskiw says. “When shoppers are looking at comparable products, they see a sea of color, but they’re all bags,” he says. “Retailers like the fact that this container draws more attention.” ❖ For more information: Kristi Sics, Huhtamaki Systems, 913-583-8263 Stephen Key, Spinformation Co., 209-668-9478

www.foodengineeringmag.com | Food Engineering | September 2011

19

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

From leader to laggard

I

f there were a Miss Congeniality award for packaging, a food or beverage company would have been the odds-on favorite of judges for the 23rd DuPont Awards for Packaging Innovation. The industr y traditionally has dominated the DuPont awards, fitting given that three-fifths of packaging machinery is used in food and beverage applications. Innovation always has been a key criterion in the DuPont awards, but in recent years, sustainability and cost cutting have separated gold and platinum from silver award winners. Among this year’s crop of 16 honorees, only five were for food or beverage companies, and none rated more than a silver award. A dual-opening, single-serve ketchup pack from H.J. Heinz exemplified the close-but-no-cigar outcome for food packaging. A few milligrams shy of an ounce, the contents can be accessed via a laser-scored tip for squeez-

` H.J Heinz and Stonyfield Farm led a thin field of food & beverage honorees in this year’s Dupont packaging awards. Heinz created the Dip & Squeeze ketchup package (right) for foodservice customers. Yogurt cups made of 93% PLA (left) had to overcome machinability issues. Source: Dupont Packaging & Industrial Polymers.

ing or a peel-back top for dipping. Tripling the amount of ketchup in conventional squeeze packs means more prod-

ceeding expectations in the food industry.

Since the inception of food machinery lubricants, JAX has been the pace-setter in meeting — and exceeding — lubrication needs. For more than 50 years companies have relied on our expertise in not only product enhancement, but in our ability to help maintain and prolong the life of their machines through maintenance solutions tailored to each specific challenge. | Food AfterSeptember all, there’s such thing as a| cookie cutter answer — even in the food industry. 2011 no Engineering www.foodengineeringmag.com 20

800.782.8850 www.jax.com See Food Master, p. 97

“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

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

uct waste, however, and the DuPont judges take a dim view of waste. As one sustainability expert noted at the awards presentation, packaging material accounts for only 7 percent of a product’s resource inputs. Most of the rest is attributable to the product itself, and wasted product more than offsets any packaging material savings. Designed to emulate the look of a ketchup bottle, the packet’s flexible film overlaps a thermoformed tray to create the appearance of a bottle neck. Heinz shares the award with Multivac Inc., which engineered and integrated a 1,500-units-a-minute rollstock machine with a Hinds-Bock filler and Videojet laser coding machine, along with its own vision-inspection system that rejects packets with sealsurface contamination. The project represents “years of hard work and collaboration between the engineering teams,” according to Jan Erik Kuhlmann, president and CEO of Kansas City-based Multivac. In accepting the award, Heinz’s Michael Okoroafor, head of packaging R&D, suggested the greatest challenge was winning foodservice acceptance of the oversized packet. The challenge apparently was met: The first 67-ft. long packaging line was installed late last year at Heinz’s Fremont, OH plant. A third is expected to come online this fall. Stonyfield Farm was another silver winner, for yogurt cups formed from polylactic acid (PLA) resins derived from corn

starch. The biobased polymer blends 93 percent PLA with petroleum resins and elements such as Ti02 whitening pigment. Stonyfield switched from polystyrene after Clear Lam Packaging Inc., Elk Grove Village, IL, overcame PLA’s pliability limitations in developing a material that would machine at Stonyfield’s form/fill/seal machine’s 30 cycles per minute rate. Roman Forowycz, Clear Lam’s chief marketing officer, thinks the DuPont judges hope to spur innovation and favor packaging “early on in the development cycle.” PLA’s 10 years of commercial use worked against the yogurt cup, though significant improvements such as higher heat tolerance, greater flexibility and improved barrier properties have improved functionality. “A few years ago, companies were looking for absolute solutions, and there are no absolute solutions,” says Forowycz. Incremental improvements are being made, however. While the Stonyfield cup qualifies for USDA’s Biobased Product certification, the lidding material does not. Clear Lam’s engineers continue work on biobased lidding that is economically feasible, he says. ❖ For more information: Roman Forowycz, Clear Lam Packaging Inc., 847-378-1301, [email protected] Jan Erik Kuhlmann, Multivac Inc., 816-891-0555

For over 70 years, Paul Mueller Company has earned distinction as an outstanding manufacturer of stainless steel tanks and industrial processing equipment. Mueller® has evolved into a global process solutions provider, offering manufactured equipment and components, integrated process systems, and expanded-scope construction. Mueller has the technical expertise, innovative engineering, and manufacturing resources to implement a process system specific to your needs. From modular systems to complete turnkey plants, when you think of process, think…

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413

See Food Master, p. 84

22

September 2011 | Food Engineering | www.foodengineeringmag.com

“With products that taste this good, success comes naturally.” Business is booming in juice bars from Sydney to San Francisco – with a little help from Performance Food Centers. PFC is a 1-stop shop for everything a juice bar needs to be successful, anywhere in the world. PFC’s best-selling line of protein supplements are all based on whey protein blends created by GMP Nutraceuticals. Every blend comes with a knockout flavor profile created with all-natural ingredients. And we’re proud to say that every one is made in a Ross Ribbon Blender. Learn more. Call 1-800-243-ROSS Visit mixers.com

Bill Alhofen Sales Manager Ross Employee Owner

FOOD SAFETY

Fear mongering in the media

`

Frightening the public with half-truths and innuendo is not the way to teach them about food and nutrition.

A

s a food scientist, I feel it is depressing to read the newspaper or browse the Internet. So many food-related articles are loaded with misinformation, innuendo and half-truths that it is almost frightening. Not frightening in the sense that I am personally concerned, but frightened as to how these articles will affect the average consumer. For example, a testing laboratory was hired to collect poultry from supermarkets and test the product for pathogens. It reported 69 percent of the samples tested were positive for Campylobacter jejuni and 19 percent contained Salmonella. The study also reported that a large number of samples contained Richard F. Stier, S. aureus. It was almost an afterContributing Editor thought when the author mentioned poultry is usually cooked prior to consumption, a process that would kill these pathogens. If the same laboratory swabbed the hands and nasal passages of 10,000 people, it is very likely it would isolate S. aureus in 50 percent of those tested. If it tested stool samples from the same group, it would likely find E. coli in 100 percent of the samples. Does this imply people are dangerous vectors of potential food pathogens? Another article stated peanut butter is a high-risk food due to aflatoxin, a known carcinogen. The writer advised consumers to keep peanut butter in the refrigerator since that would discourage mold growth and, hence, the formation of aflatoxin. In fact, peanut butter has a very low water activity which inhibits mold growth. In addition, most peanut butter processors monitor their raw materials, i.e., peanuts, for aflatoxin. An April 9, 1989 San Francisco Chronicle article written by the late Art Hoppe was titled “Safe at Last.” Mr. Hoppe wrote facetiously about a character named Harold Feckley, who was described as a cautious man who gave up “bacon because of nitrates or nitrites (he was never sure which).” He then boycotted eggs because of cholesterol, chicken because of Salmonel-

la, fish because of mercury and conventionally grown vegetables due to pesticides. This reduced poor Harold to a diet of organically grown rutabagas, alfalfa sprouts and spring water. He even moved out of his house because of a fear of radon. With his wife telling him everything would eventually be tested and found hazardous, Harold decided he would be safe only if he buried himself in an organic hole inside an organic pine box. The moral of the story: “What you don’t know is all that keeps you going these days.” This article was written 22 years ago, yet it could have been written today. Frightening the public with half-truths and innuendo is not the way to teach people about food and nutrition. Food laws and regulations mandate the food processing industry produce safe, wholesome foods. Those companies that fail to do so will fall by the wayside. With the advent of the Food Safety Modernization Act of 2010, the segment of the industry regulated by FDA will have additional controls imposed. These controls will be new on the regulatory side, but they will not be new for those operations that have made a commitment to the production of safe, wholesome foods. However, many other companies will be forced to upgrade quality, safety and sanitation programs. The food industry must step forward to publicize not only what it is doing to ensure the foods it produces are safe, but make a commitment to public education. Unfortunately, many processors have been advised by their attorneys not to speak publicly about what they do to ensure food safety and quality. The feeling is that this information could be used against them if there is a problem. Perhaps the best route would be for the food industry to make an effort to resuscitate the food science extension—a group that works with industry and the public to provide education. Someone must step forward now and provide the public with proper information. ❖

www.foodengineeringmag.com | Food Engineering | September 2011

25

FOOD SAFETY

` U P DAT E

PROTECTIVE APPAREL

FOOD PROCESSING COAT UniFirst Corporation’s UniWeave knee-length food processing coat is available in five distinct colors to assist in eliminating cross-contamination threats by allowing food processors to identify food handlers from non-food handlers, or workers who may be outside their assigned work areas. The coat is 100 percent spun polyester and features snap closures, and an inside lower pocket; it can be obtained with either open or elastic knit cuffs. The colors available are: grey, navy, tan, white and light blue. UniFirst Corp; 800-225-3364; www.unifirst.com

MATERIAL MASTER ™

Dolphin Products provides a range of food industry protective clothing for use in processing applications. Products include bouffant caps; hair nets; disposable lab coats, coveralls, sleeve covers and gloves; heat-resistant oven wear; and a variety of industrial gloves. Most products are available in several types and materials. For example, aprons are available in eight types including vinyl PVC, urethane, polypropylene, laminated and microporous types. Dolphin Products; 800-700-8704; www.dolphinproducts.com

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26

September 2011 | Food Engineering | www.foodengineeringmag.com

Rapid Microbial Testing Introducing the BD FACSMicroCount

™

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.

BD, BD Logo and all other trademarks are property of Becton, Dickinson and Company. © 2011 BD 23-13070-00

BD Biosciences 2350 Qume Drive San Jose, CA 95131 bdbiosciences.com

FOOD SAFETY

` U P DAT E tion of the exposed Staphylococcus aureus bacteria (meets ASTM E2149). It has strategically located snaps for easier detection in metal detection machines. CINTAS; 800-246-8271; www.cintas.com

TREATED FABRIC GARMENTS

REUSABLE BOUFFANT The CINTAS antimicrobial bouffant cap provides an alternative solution to disposables; testing has shown it to be four times cleaner than disposable caps. Not only is the cap well served in food processing applications, it is better for the environment as it can be used over and over. The cap shows a greater than 99.9 percent reduc-

Developed by Milliken, BioSmart textile technology binds chlorine molecules to the surface of fabric. Chlorine on the fabric continues to kill germs long after the fabric has been washed. BioSmart-treated fabric is used to create garments and towels for the food industry, available through G&K Services ProSura Food Safety Solutions program. When these treated fabrics are laundered according to care instructions with EPA-registered chlorine bleach, the chlorine kills 99.9 percent of common bacteria and viruses, including Salmonella choleraesuis, E. coli, Staphylococcus aureus and Hepatitis A. The treated fabrics have passed ISO skin irritation and skin sensitivity tests. G&K Services; 800-452-2737; www.gkservices.com

FULL-SERVICE UNIFORM/ ACCESSORIES RENTAL ARAMARK provides uniform rental and leasing services to more than 200,000 customer accounts in 46 states from over 200 service locations and distribution centers across the US. The company’s full-service employee uniform solution includes design, sourcing, manufacturing, delivery, cleaning and maintenance. The outfitter offers food processors a total HACCP uniform solution that helps them to solidify their image, promote teamwork and motivate employees. The HACCP solution includes a proprietary set of strict sanitary standard operating procedures, HACCP-trained employees, ATP testing and documentation, specialized wash formulas developed by Ecolab, protected and clean transportation of garments and a wide variety of specialized food processing garments, including disposable items and personal protective equipment. ARAMARK; 800-272-6275; www.aramark-uniform.com

We’ve got sssssteam heat... Ready to shift your food production to a more favorable continuous process? The new Wenger Thermal Twin Screw Extruder allows previously unheard of high levels of thermal energy for a more gentle cooking process compared to high-shear cook. Products high in corn or rice content can be processed without the stickiness typically encountered in conventional extrusion systems. The new Thermal Twin design allows ingredients to be fully cooked without damage to the starch or protein matrix. The unique screw profile, combined with an innovative extruder barrel design permits up to four times steam injection for unprecedented savings in both energy costs and equipment wear. Get details now on the revolutionary Thermal Twin Screw Extruder Series, with flexibility to meet your specific needs, at www.wenger.com. At Wenger, we innovate to solve customer challenges.

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See Food Master, p. 132

28

September 2011 | Food Engineering | www.foodengineeringmag.com

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TECHNOLOGY S O U R C E B O O K Focus on Metal Detection, X-ray and Mixing & Blending Equipment

FLUID-DRIVEN TANK CLEANER

DROP-IN REPLACEMENT BELT A drop-in replacement for standard and wide belt stackers, Ashworth ExactaStack selfstacking spiral belt is available in all widths, tier heights and mesh configurations for both spliced-in sections and complete belt replacements. No system drive modifications are required when the belt is used as a drop-in replacement. Ashworth Bros., Inc.; 800-682-4594; www.ashworth.com

to be mounted close to a mixer in a hazardous area and wired to a variable frequency drive installed outside the mixing room. Type X or Z purge control panels are available for mixer portability without remote wiring. Charles Ross & Son Company; 800243-ROSS; www.mixers.com

2,000-GAL. MIXING KETTLES

MIXER CONTROL PANEL Ross SysCon mixer explosion-proof control panels have an operator station that includes a digital readout for speed and cycle time. They are designed

Lee 2,000-gal. dual-motion mixing kettles have full jacketing, heavy-duty agitators and a sanitary ball valve outlet. The kettles provide consistent mixing and heat-up and cool-down cycles. They are fabricated from Incolloy, a highly corrosive-resistant alloy. Lee Industries, Inc.; www.leeind.com

Using external gears to reduce nozzle speed, the Spraying Systems TankJet 75 fluid-driven tank cleaner provides medium-impact impingement cleaning of tanks, totes and intermediate bulk containers; it cleans tanks up to 30 ft. in diameter. The unit features rotating solid stream nozzles that complete a 360° indexing pattern every 45 revolutions. It is available with a 2- or 4-nozzle hub and can be mounted permanently or moved from tank to tank. Spraying Systems Co.; 630-6655000; www.spray.com

TUBE MAGNETIC SEPARATOR Designed for use with highly abrasive products in pneumatic transfer applications, the Industrial Magnetics dual-door EP tube magnetic separator has a housing consisting of 2 door-mounted magnetic plates positioned on opposing sides of a stainless steel tube matching the existing diameter of the processing line. The design allows the unit to reach through the entire product stream and capture metal contaminants from a fast-moving flow. Industrial Magnetics, Inc.; 800-6624638; www.magnetics.com

www.foodengineeringmag.com | Food Engineering | September 2011

31

TECHNOLOGY S O U R C E B O O K

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MIXER/BLENDER Used for the sanitary mixing and blending of meat and food products, the Mepaco Model 170 mixer/blender reduces blending times and improves homogeneity and consistency with minimal temperature rise. The unit offers flexible options for cooking, cooling, grinding, massaging and more. The mixer/blender is available in a range of sizes and with an optional electropolished tub and agitators to limit product adhesion to the side walls and agitators, and evacuate blended product at the end of the cycle. Mepaco; 920-356-9900; www.mepaco.net

DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934 defranciscimachine.com [email protected] 321-952-6600

See Food Master, p. 49

DRAWER MAGNETS

FLANGED CONNECTOR CLAMPS

Puritan drawer magnets provide equipment and product protection from medium and fine ferrous contaminants in dry, free-flowing products under gravity flow. As product flows through the stainless steel housing, it cascades over multiple, staggered rows of magnetic tubes. Ferrous contaminants are pulled to the surface of the magnets where they move to the underside of the tubes to prevent washoff. Cleaning the magnetic tubes is accomplished by releasing the latch assembly, opening the door, removing the grate assemblies one at a time and removing the tramp metal with gloved hands. Puritan Magnetics, Inc.; 248-628-3808

Winco RoHS-compliant GN 146.3 metric size, aluminum flanged connector clamps, round bore type, come black powdercoated, with a textured finish or tumbled with a matte shot-blasted finish. The cap screws are DIN 912, steel, zinc plated; the nylon insert hex nuts are DIN 985, steel, zinc plated. The clamping bores are machined and designed for construction tubings GN 990 or DIN 2391, DIN 2395 and DIN 2462. Kits are available that replace the cap screws with adjustable levers, and include lever, spacer bushing and hex nut. Versions with stainless steel cap screws and hex nuts are available upon request. J.W. Winco; 800-877-8351; www.jwwinco.com

September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

CHEESE COOKER The Blentech Infinity twin-shaft, horizontal-designed cooker is used for continuous cheese processing. Equipped with multiple 360° direct steam infusion jets, the unit is suitable for high- or low-volume production. Blentech Corporation; 707-523-5949; www.blentech.com

9KVJ6QVCN2TQFWEV+PURGEVKQP6JG$GPGƂVU Are Clear From Every Angle & Every Stage Of The Packaging Quality Process HI-Speed Checkweighing

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PACK CONVEYOR The Heat and Control progressive pack conveyor can be integrated with a variety of Ishida weighers to suit fresh, frozen or dry product applications. The weigher deposits each product charge into a diverting timing hopper centered over the conveyor. The conveyor has 2 flighted center belts to accept product charges and independent variable-speed packing conveyors on each side. The system can be configured in 3 ways depending on the product being packed: charge pack by hand, charge pack by weigher and progressive pack. The conveyor can be built with removable work tables and up to 10 operator positions. Heat and Control, Inc.; 800-2275980; www.heatandcontrol.com

DISINFECTANT/SANITIZER PURE Bioscience PURE hard surface disinfectant and food contact surface sanitizer contains silver dihydrogen citrate (SDC) antimicrobial, which has received GRAS self-affirmation when used on food processing equipment, machinery and utensils. EPA-registered for use on food contact surfaces, the disinfectant/sanitizer has 30-second bacterial kill times and 24-hour residual protection. It kills resistant pathogens like MRSA and eliminates food pathogens such as E. coli, Salmonella and Campylobacter, as well as fungi and viruses including Norovirus, HIV, Influenza A, Avian Influenza and H1N1. PURE Bioscience, Inc.; www.purebio.com

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www.foodengineeringmag.com | Food Engineering | September 2011

33

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

PNEUMATIC LINE MAGNETS Used to remove fine metal contaminants in dilute-phase pneumatic conveying, MPI pneumatic line magnets have a sanitary design in all product contact areas, quickrelease clamps, 100% stainless steel product areas and rare earth magnet material. A food-grade, closed-cell gasket offers a permanent seal. Also available is a seam-welded, magnetic, stainless steel “raised” pole design that improves tramp metal retention between cleanings. Magnetic Products, Inc.; www.mpimagnet.com

the detector has a universal power input allowing switchless operation from either 120VAC to 240VAC. Multiple detectors can be monitored and controlled from a single PC using Eriez free E-Z Link software. Eriez; 888-300-ERIEZ; www.eriez.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. To learn how Clarion can refine your operation, call 855-MY-CLARION or visit clarionlubricants.com.

X-RAY SYSTEM

METAL DETECTOR The Eriez E-Z Tec DSP metal detector combines a 4- x 5-in. (1/4 VGA) touch screen interface with digital signal processing. The touch screen interface allows users to view multiple line items at once; all numeric data and value entries are made through an on-screen, calculator-type interface. Used with wet (conductive) or dry products, See Food Master, p. IFC 13, 36-41

Capable of detecting metal, glass, dense plastics and other contaminants in packaged food, the Thermo Scientific Xpert C400 X-ray system can also analyze an X-ray image to estimate weight or fill and count or assure that objects are inside a packaged item. The system’s detectors are available in multiple resolutions; its suite of algorithms can find small contaminants in complex images. An 85W X-ray source reduces the system’s shielding requirements. The system meets IP65 requirements for dust and washdown and operates over a 5°C to 40°C temperature range. Thermo Fisher Scientific Inc.; www.thermofisher.com

September 2011 | Food Engineering | www.foodengineeringmag.com

IMAGINE A WORLD WITHOUT CONTAMINATION OR DOWNTIME.

FOOD GRADE

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

clear. safe. solutions.

TECHNOLOGY S O U R C E B O O K

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

S O N I C

VT

TA N K

TM

DRYER

Huge increase in production time for tanks, blenders & totes P AT E N T E D

TM

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

METAL DETECTOR Designed to examine liquid and pasty types of food products, the Bunting Magnetics Meatline 05 0 metal detector detects and separates encapsulated or free metal. It features a reject mechanism that can be taken apart without tools. All components are linked together with a chain. The unit fits all commercial vacuum fillers, is pressurewasher safe, has a stable frame with lockable casters and a permanently maintenance-free pneumatic drive. All components are made of stainless steel or food-safe plastic. Bunting Magnetics Co.; 800-835-2526; www.buntingmagnetics.com

FLUID GEAR GREASE

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

®

AIR SYSTEMS

36

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

September 2011 | Food Engineering | www.foodengineeringmag.com

Based on highly refined synthetic hydrocarbon and a special calcium complex soap thickener, Klüberfood NH1 94-6000 synthetic fluid gear grease is NSF H1 registered and safe for incidental food contact. Offering wear protection, corrosion protection and water resistance, it can be used as gear grease for the immersion lubrication of toothed and worm gears or chains, and other friction points such as bearings and linear guides. Klüber Lubrication North America L.P.; www.klueber.com

TECHNOLOGY S O U R C E B O O K

REUSABLE PALLET Used in both stacking and lightweight racking applications, the ORBIS 40.0 in. x 48.0 in. x 5.9 in. reusable Stack’R pallet is 100% recyclable and can to stand up to a variety of temperatures and harsh environments. Highly cleanable for use in all types of food processing plants, the structural foam-molded pallet is smooth and non-porous to avoid absorbing moisture or odors. ORBIS Corporation; 888-307-2185; www.orbiscorporation.com

PORTABLE MIXERS Fitted with industry-standard NEMA motors and gear motors from 1/4 to 5hp, Chemineer portable DT mixers come with a range of impellers, shaft lengths and diameters with flanged or chuck shaft couplings. They feature a cast aluminum housing and multi-directional clamp for horizontal and vertical adjustment. All-stainless steel housings and motors are available. Chemineer, Inc.; 800-643-0641; www.chemineer.com

POSITIONING MOTION CONTROLLER Designed for volume OEM applications, the Dunkermotoren compact, 4-quadrant positioning motion controller with integral output stage is used to control brushless and brushed DC motors as a slave in CANopen networks or standalone operation with digital or analog IO. For 4-quadrant digital speed control, the controller can be commanded to run in either direction, stop and hold with torque, and stop without torque through digital inputs. Other inputs can switch between programmed speeds or allow for a variable analog speed reference. Accel/decal ramps for the motor can also be programmed. The controller protects against over-voltage, low voltage and excessive temperature. Dunkermotoren USA Inc.; www.dunkermotoren.com

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 www.foodengineeringmag.com | Food Engineering | September 2011

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TECHNOLOGY S O U R C E B O O K

WATER POLISHING TECHNIQUES GEA water polishing techniques enable dairy plants to recycle process water for cleaning purposes; with further treatment, the water can be sufficiently polished for it to be used for processing. The sweet “white water” from the cleaning process can also be collected and treated using reverse osmosis to allow the solids recovered to be returned to the process (for example, to increase the solids content in yogurt milk). GEA Filtration; www.geafiltration.com

OUR PRIORITY:

YOUR SAFET Y SLIP RESISTANT METAL FLOORING PRODUCTS

IMPELLER PUMP CART The ITT- Jabsco VeraFlex FIP flexible impeller pump cart system offers up to 60gpm (with variable frequency drive), while incorporating gentle pumping action to carefully handle thin, viscous and particle-laden fluids. The minimal meshing action and lowspeed capability of the pumps allow both viscous fluids and solid particles to pass through undamaged, including cream fillings, jams and pie fillings with fruit pieces. The pumps can also process cheese without damage and eliminate unwanted butter granules or homogenization of the milk. The system is available with an optional wired or wireless remote. ITT Flow Control; 714-557-4700; ittflowcontrol.com

METAL DETECTOR

SlipNOT® Metal Safety Flooring

Pack Expo Booth # C-4819

www.slipnot.com | 800-754-7668 38

September 2011 | Food Engineering | www.foodengineeringmag.com

The Fortress STEALTH metal detector has digital signal processing technology for high-speed precision detection; ultra-sensitivity levels detect the smallest metal contaminants. The detector includes automatic testing and calibration. Testing for quality assurance using samples can be initiated on demand or by time interval. The control panel features secure password protection and multi-language options. Individual settings can be stored in the product library and recalled instantly when required. Dual power/frequency facilitates automatic compensation for extreme product characteristics. Fortress Technology Inc.; 888-2208737; www.fortresstechnology.com

TECHNOLOGY S O U R C E B O O K

TRAY INDEXING CONVEYOR Configured to run with the NuTEC 720 food forming machine, the NuTEC automatic direct depositing and tray indexing conveyor portions and deposits patties directly into trays at speeds up to 65 trays/min. The completely hydraulic 720 forming machine features a 300lb. hopper and has a variable speed of 15 to 65 strokes/min. Its usable mold plate area is 9-in. wide x 6 in. front to back, with a mold plate thickness of 1/8 in. through 1 1/4 in. NuTEC Manufacturing; 815-722-2800; www.nutecmfg.com

X-RAY INSPECTION Anritsu KD7400 X-ray inspection systems offer an exacting means of detecting bones and other larger, low-density items while minimizing product effect; they differentiate between product and contaminant by providing both a low- and high-energy X-ray level. The units are designed for use in the poultry industry, where bones are exceptionally difficult to detect; for detecting glass and stone in bulk nuts/grains; and for items that are 50mm high or less. Anritsu Industrial Solutions USA Inc.; 847-419-XRAY; www.detectionperfection.com

BALL VALVES Available in sizes from 1/2 to 4 in., SVF Series SBC9 3-piece ball valves come standard with a 316 stainless steel body, SUS316 stem, TFM1600 seat and stem seal and body seal, and mechanically polished internal surface finish. End connections include tri-clamp and extended tube OD. Other features include a builtin ISO 5211 direct mounting pad, antistatic device, blowout-proof stem and locking device. SVF Flow Controls, Inc.; 800-7837836; www.svf.net

Serving the Food & Beverage industry for over 100 years

VISIT US AT PACK EXPO For an exclusive look into everything you need to know about plant expansions and construction, stop by Booth #6602 at PACK EXPO to request your FREE copy of “Creating Food and Beverage Facilities from Concept to Completion” A company built on delivering “Results, Not ExcusesTM”

Please contact us at [email protected] or www.theaustin.com/foodgroup CONSULTANTS

DESIGNERS

INTEGRATED PROJECT DELIVERY ENGINEERS

CONSTRUCTORS

If you are interested in FREE registration to PACK EXPO, please contact Jennifer McKenzie at [email protected]

www.foodengineeringmag.com | Food Engineering | September 2011

39

TECHNOLOGY S O U R C E B O O K

WATERPROOF DIGITAL THERMOMETER The Omega DP8891 series waterproof digital thermometer with probe features a wide temperature range and can be used as a portable unit or a wall-mounted large LCD meter. Designed for monitoring temperature in food processing applications where a battery-powered instrument is required and there may be exposure to water splashes, it is Celsius and Fahrenheit switchable. Omega, Inc.; 1-800-TC-OMEGA; www.omega.com

www.amerivap.com

Steam Generator

Jet System

Uses only ounces of water per minute, not gallons per minute!

Brush System

• ADJUSTABLE • PROGRAMMABLE • PORTABLE • POWERFUL • ENVIRONMENTALLY SAFE • SUSTAINABLE

JET SYSTEM

BRUSH SYSTEM

A portable steam cleaning machine specifically designed to clean and sanitize plastic mesh and wire conveyor belts.

A portable steam cleaning machine specifically designed to clean and sanitize continuous flat conveyor belts.

• • • • • •

Improve Safety, Health and Quality Inspection Results Reduce System & Line Down Time Save Money: Cut Labor & Chemical Costs Drastically Reduce Water Consumption Eliminate Water Waste Reduce Toxic Waste: Be More Eco-Friendly & Reduce Disposal Costs

First. . . Best . . . Different

AmeriVap® Systems, Inc. | Phone 404.350.0239 | Fax: 404.350.9214 Email: [email protected] See Food Master, p. 10

40

September 2011 | Food Engineering | www.foodengineeringmag.com

Higher standards of sanitation are now possible in an environmentally responsible way.

The Houdini Brush and Jet Systems work tirelessly insitu, sanitizing as they clean without chemicals, and with very little water usage.

NEMA TYPE INVERTER Engineered for demanding food and beverage processing, conveying and fan/ pump control applications, the SEWEurodrive Movitrac LTE NEMA Type 4X/ IP66 inverter has predefined parameter settings and a user-friendly keypad for “plug-in and drive” start-up. The drive contains dust-tight seals to deliver reliable performance even under high-pressure washdowns. The unit covers a power range from 1/2 to 10hp for operation in single- and 3-phase power supply systems, and can withstand 150% overload for 60 seconds. Options include a power switch, potentiometer and 32kHz “quiet switching” for silent motor operations. NEMA Type 1/IP20 and NEMA Type 12/ IP55 models are also available. SEW-Eurodrive; www.seweurodrive.com

AIR POWER SYSTEM Designed to produce oil-free or instrument-quality compressed air, the Sullair stationary air power system consists of a rotary screw air compressor, wet storage tank, refrigerated or regenerative dryer, customized filters, dry storage and flow controller. It also includes an oil/water separator and drains, and Ethernet-based eConnect to monitor and control the entire system. Sullair Corporation; 219-879-5451; www.sullair.com

TECHNOLOGY S O U R C E B O O K

AIR-OPERATED PUMPS Designed for demanding solids-handling applications in the food and beverage industry, Wilden Saniflo Series VC metal pumps are suitable for processes requiring the delicate handling of whole strawberries, mixed vegetables, meat products or waste products. Available in 4-, 6- and 8-in. sizes, the air-operated, electrically controlled pumps require little or no water and can handle solids up to 6 in. in diameter. Wilden; www.wildenpump.com

Fry more in your existing line space. COUNTER MODULE Featuring up to 8 channels and hot-swappable functionality, the Advantech APAX5080 counter module for use in automated systems is capable of simultaneously taking counts from multiple sources using any of its 5 operating modes (Up, Up/ Down, Frequency, Pulse/Direction and A/B Phase). Four digital input counter gates define when the counter is enabled; 4 digital output alarm channels are triggered when certain criteria are met. The counter is configured using Microsoft Windows CE, Linux and SoftLogic. Advantech Corporation, Industrial Automation Group; 800-205-7940; www.advantech.com

Replace your existing direct-heated fryer with a Breaded Products Fryer and get more production output in the same space or less. BPF temperature control is more precise. Low system oil volume produces fast oil turnover rates. And all oil is filtered once every minute on average. Contact us to get greater fryer output and efficiency in less space.

SEAL/BEARING MATERIALS Trelleborg Turcon MF6 and Zurcon Z431 PEEK seal and bearing materials have third-party verified declaration of conformance to the latest version of 3-A Sanitary Standard 20-27. Capable of withstanding high temperatures and the cleaning regimes used in food and beverage manufacturing, the compounds provide tribological and sealing capabilities. The materials have also passed migration tests for aqueous, acidic and fatty foods in repeated contact according to directive 2002/72/EC and FDA extraction tests according to 21CFR177.2415. Trelleborg Sealing Solutions; www.tss.trelleborg.com

New BPF length

Existing fryer length

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

www.foodengineeringmag.com | Food Engineering | September 2011

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EX03074Mart_1.indd 1

TECHNOLOGY S O U R C E B O O K

POWDER MIXER

2/21/07 2:43:26 PM

Capable of blending of wet and dry ingredients into a fluid stream, the Fristam powder mixer has a proven pump and blender system. The mixer produces consistent batches; destroys lumps, clumps and fisheyes; and shortens process times. It handles flow rates up to 375gpm and powder induction rates up to 600 lbs./min. Fristam Pumps USA; 800-841-5001; www.fristam.com

PARTITION OPENER/INSERTER Suitable for packing glass or fragile products into cases requiring a chipboard partition, the A-B-C Model 70 partition opener/inserter features twin servos that drive the partition indexing, opening and inserting. Lateral stabilizers square the partition and ensure smooth insertion into the waiting case or tray. All parameters are stored for immediate recall at the control console. A-B-C Packaging Machine Corporation; 800-237-5975, www.abcpackaging.com

September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

TAIL TUCKER Designed for food and beverage applications, the ITW Muller tail tucker eliminates loose film tails on stretch-wrapped pallets. The unit’s arms extend down prior to the last 3 wraps of the cycle and are wrapped along with the load by 2 full webs of film. During the last one-half revolution in the cycle, the 20-in. web of film is formed into a rope, which is captured by the tail tucker arms, cut and held in one arm to begin the next cycle. The remaining cut end of the film is held by the other arm. As the ring frame moves to the top of the machine, it pulls the rope behind the last 2 full webs of film and is released after it reaches the top of the load. The tail tucker is available as an enhancement to the ITW Muller Octopus line of stretch-wrap equipment or as a retrofit to most existing machines. ITW Muller; 800-628-6787; www.itwmuller.com

COLOR-MATCHING SOFTWARE KMSA COLIBRI version 3.6.4 software is designed for efficient recipe formulation and the correction of opaque, translucent and transparent colors in paints and plastics. The template function allows users to predefine the software features and screen layout to their needs and applications. The software has full enterprise network capability, connecting an unlimited number of users worldwide via the web to share a central database. It can create fully customizable single and multiple QC job reports for statistical analysis, provides a custom display of QC data and includes a Konica Minolta FD-7 spectrodensitometer driver. Konica Minolta Sensing Americas, Inc.; www.konicaminolta.com

INDUSTRIAL FLOOR TILES Designed for food and beverage companies that require sanitary flooring for their processing facilities, Henkel TUFCHEM impervious, sustainable industrial tiles contain 4% recycled material. The fully vitrified 3/4-in. thick porcelain tiles automatically qualify for indoor air quality credits toward LEED Certification; projects in the vicinity of the tile manufacturing and raw material extraction sites may qualify for regional materials credits. Henkel Corporation; 919-765-0157

www.foodengineeringmag.com | Food Engineering | September 2011

See Food Master, p. IFC 14

TECHNOLOGY S O U R C E B O O K

For consistant food grade lubricant quality, buy from a company that is NSF H1 and ISO 21469 CERTIFIED. Summit Industrial Products is one of the fast growing synthetic food grade lubricant manufacturing companies in the US.

Try us out and see why!

AIR KNIVES Suitable for blowoff, drying or cooling applications, EXAIR air knife systems meet the safety, health and environmental standards of the European Union and have attained the CE mark. The systems entrain high volumes of room air; they can be mounted to accommodate a variety of industrial applications involving conveyors and webs. The knives are manufactured in aluminum, stainless steel and PVDF for corrosive environments. Stock sizes range from 3 to 96 in. Special order lengths are available. EXAIR Corporation; 800-903-9247; www.exair.com

cable, connector, terminal box, integrated brake and/or encoder, special shafts and special flanges are available. Electro ABI B.V.; www.abi.nl

ISO 9001:2008 KOSHER CFIA HALAL

800.749.5823 www.klsummit.com

SUMMIT

INDUSTRIAL PRODUCTS

ASEPTIC MOTORS Designed for sectors with high standards in hygiene and cleaning, Electro ABI completely stainless steel aseptic electric motors and gear motors feature a smooth surface with no irregularities or cooling fan. The body is manufactured out of AISI 304, DIN 1.4301; the shaft is made of AISI 420, DIN 1.4021. The enclosure of the motors is IP69K rated and provides absolute ingress resistance, even in applications subject to frequent high-pressure cleaning with acid or alkali-based cleaning agents. The efficiency of motors from 750W and up is classified as IE3. Motors with

SEPARATOR Available in 48- and 60-in. diameter models, the SWECO Super MX separator provides forces as high as 10 Gs and speeds up to 2,200rpm. Features include an external conical motor tube gusset, 5hp motor with extra-large bearings, heavy springs, thick frames and spouts, and heavyweight guards. SWECO; 859-371-4360; www.sweco.com

September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

The Perfect Fit for Your Precision Equipment

WATER HEATER

MACHINE SAFETY Available with selectable 30, 40, 50 and 70mm resolutions, the Omron OS32C safety laser scanner can be used for an array of area and machine safety applications, including point-of-entry hand detection and instances where safety light curtains are too large to fit or may impair productivity. The Version 1.4.2 of the OS32C configuration tool enables users to copy and paste zones and zone sets, offers record system monitoring and playback to help troubleshoot false nuisance intrusions and includes a configuration checksum functionality to help identify program tampering. Omron Scientific Technologies Inc.; 800-479-3658; www.sti.com

Centrifuges have a demanding job. Protect them with expert service, repairs and genuine replacement parts: the three cornerstones of Westfalia Separator® capitalcare. Only GEA Westfalia Separator has two authorized North American repair shops and strategic parts inventories housed near customer locations to assure availability whenever and wherever parts are needed. Our all encompassing program was developed to protect equipment and ensure safe, reliable operation and maximum productivity. To learn more contact Klaus Brinkrode at 201-784-4335, or [email protected].

Liquids to Value GEA Mechanical Equipment US, Inc.

GEA Westfalia Separator Division 100 Fairway Court · Northvale, NJ 07647 Phone: 201-767-3900 · Fax: 201-767-3901 Toll-Free: 800-722-6622 24-Hour Technical Help: 800-509-9299 See Food Master, p. 65 www.wsus.com

1522T

Engineered for food service, the Heatec Firestorm water heater is certified in accordance with NSF/ANSI Standard 5; all parts of the heater that contact the water it heats are lead free. On-demand water heating eliminates the need for water storage tanks. Available with outputs up to 36 million BTU/hr., the heater has a thermal efficiency of 99%. Heatec; 423-821-5300; www.heatec.com

TECHNOLOGY S O U R C E B O O K

VALVE Capable of handling dry bulk solids in gravity flow, dilute phase or vacuum conveying applications, the Vortex Quantum Series Orifice Gate valve features a full-flange, weather-resistant design and fewer replacement parts. The blade and seal design allows the valve to “self-clean” on the opening stroke, preventing material from packing on its internal seals. Sizes range from 2 in. to 14 in. Vortex Valves North America; 785-825-7177; www.vortexvalves.com

September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

HOTFILL/RETORT CLOSURE Designed for hotfill and retort applications such as soup, nutritional beverages, coffee and tea, the Crown 40mm Ideal closure is compatible with plastic or glass containers. The closure has a plastisol-lined metal disk that forms an airtight seal against the container to guard against oxygen ingress and an easy-to-grip plastic band. Logos, messaging and nutritional value can be printed on the metal disk; different flavors can be communicated with the colored plastic bands. The closure is fully recyclable. Crown Holdings, Inc.; www.crowncork.com

www.foodengineeringmag.com | Food Engineering | September 2011

See Food Master, p. 73

TECHNOLOGY S O U R C E B O O K

STORAGE CARRIER The Kardex Megamat RS Vertical Carousel carrier features an interchangeable design, allowing food operations to mix, match and change storage configurations. Each unit comes standard with a 0.3-in. front lip to prevent stored goods from migrating out. Carrier depth or height clips can be added, providing a taller or deeper front lip to secure varioussized totes or boxes from migrating out of the carrier. A partial top prevents overloading. Kardex Remstar, LLC; 800-639-5805; www.kardexremstar.com

TANK-WASHING The BETE HydroWhirl Poseidon cleanin-place rotating tank-washing nozzle combines slow-moving rotation with a high-impact spray pattern. A bearingless design provides a nearly constant rotation speed over the operating pressure range. Self-cleaning and media lubricated, the nozzle is made from FDAapproved materials for use in clean-inplace applications. Six standard models, each with 8 or 9 different connection options, are available. The nozzle is suitable for a range of tank sizes up to 22 ft. in diameter. BETE Fog Nozzle, Inc.; 413-7720846; www.bete.com

PLATINUM-CURED SILICONE TUBING Suited for food and beverage applications, NewAge Industries Silcon Med-X platinum-cured silicone tubing contains no plasticizers that can leach out and cause flow contamination or tube hardening. The tubing is pliable and does not support bacteria growth. It can be reused after sterilization by autoclave or gamma radiation. Standard sizes range from .030 to .625 inches I.D. Other sizes, durometers and colored tubing can be custom ordered. NewAge Industries, Inc.; 800-5063924; www.newageindustries.com See Food Master, p. 68

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September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K

EXPLOSION VENT Providing lower burst pressure (pstat) in smaller sizes, the Oseco MV-RD explosion vent protects personnel and equipment during deflagrations in high-cycling applications in areas that experience vacuum pressures up to 12psig/24.4 inHg and has a high-vacuum rating of -12psig/24.4 inHg. The vent meets the requirements of the OSHA Combustible Dust National Emphasis Program and NFPA 68. Oseco; 800-395-3475; www.oseco.com

The Healthy Alternative for Snack Expansion. AeroExpanderTM provides continuous hot air expansion of pelleted snack products with exceptional texture and appearance. Unmatched uniformity with 100% pellet expansion is achievable on a wide variety of products. Develop the industry’s next better-for-you snack with Buhler Aeroglide.

SMALL CHARACTER PRINTER Used for applications requiring easily readable variable data codes on dark or difficultto-mark materials, the Videojet 1710 small character continuous ink jet printer uses high-contrast, pigmented inks to create bright, clean codes on surfaces for which dye-based inks are not effective, such as colored glass, rubber tubing, plastic cabling and dark paperboard. The printer applies up to 5 lines of high-resolution print at speeds up to 888 ft./minute, and can print a variety of fonts in multiple languages, as well as linear bar codes, 2D DataMatrix codes, custom logos and graphics. Videojet Technologies Inc.; 800-8433610; www.videojet.com

Buhler Aeroglide 100 Aeroglide Drive, Cary NC 27511 USA Tel +1 919 851 2000, Fax +1 919 851 6029 [email protected]

BUTTERFLY VALVE The Asahi Type 57IL Isolator Lug butterfly valve has 316 stainless steel lugs that are inserted into the valve body during the injection molding process, permanently combining the lugs and valve body into one unit; the design permits removal of the downstream flange while maintaining full upstream line pressure. The valve features a non-wetted, low-profile valve stem; ISO 5211 top flange mounting pattern; full seat liner design; and molded padlock provision for lever handle models. Asahi/America, Inc.; 800-343-3618; www.asahi-america.com

Innovations for a better world. See Food Master, p. 24 www.foodengineeringmag.com | Food Engineering | September 2011

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TECHNOLOGY S O U R C E B O O K

PHOTOELECTRIC SENSOR Intended for use in heavy-duty environments, the Banner TM18 EZ-BEAM compact photoelectric sensor has a nickelplated, die-cast zinc metal housing and completely epoxyencapsulated electronics. Rated IP69K, the unit features a right angle shape, 18mm threaded barrel mount and integral all-metal M12 quick disconnect. The sensor has visible red emitter LEDs in opposed, polarized retroreflective, diffuse and fixed-field (background suppression) modes. Models with 3-wire I/O block-compatible or 4-wire complementary NPN or PNP outputs are available. Banner Engineering Corp.; 888-373-6767; www.bannerengineering.com

Reimelt adds its world-renowned expertise to Zeppelin’s proud tradition of excellence A world leader in the design, manufacture, and supply of highly automated and integrated materials handling systems for powders and liquids, Reimelt systems are installed in world-class food and beverage companies around the globe. Continuous dough mixing/kneading technology, frying systems, and fermentation systems complete our vast offering of food manufacturing solutions. • • • •

Process Technology and System Development Automation Engineering Components, Service, & Support Codos® System for continuous process mixing & kneading

Growing stronger... to serve you better!

Tel: 813-920-7434 | [email protected] | www.zeppelin-usa.com 50

September 2011 | Food Engineering | www.foodengineeringmag.com

TECHNOLOGY S O U R C E B O O K High-Speed Doors for the Food & Beverage Industry

ANTIBACTERIAL FILM Derprosa plastic polypropylene film for packing food such as fresh vegetables, prepared salads or cut greens includes an antibacterial agent that reduces bacteria proliferation on its surface by 99.9%, including E. coli and Staphylococcus aureus. The film has anti-fog properties and does not affect the quality of the packed product. Derprosa; www.derprosa.es

25<7(&

P‡*

FR U\WHFGRRUV

GOOD NEWS!

Never recondition your lobe pump again New 20 year warranty on Sine pump housing • Low shear pumping protects product integrity • No pulsation or meshing rotors • One shaft, one seal and one rotor for less maintenance than a rotary lobe pump • High flow, high suction capabilities on viscous products reduce cavitation and extend pump life

masosine.com

Food and Beverage Division MasoSine

Bredel

Watson-Marlow

See Food Master, p. 129

800-282-8823

www.foodengineeringmag.com | Food Engineering | September 2011

51

TECHNOLOGY S O U R C E B O O K

THERMOELECTRIC COOLERS McLean thermoelectric coolers for cooling electronic components in small indoor or outdoor electronic enclosures deliver 60, 100 or 200 watts of cooling for applications including telecommunications, battery cabinets, industrial enclosures, security systems and more. Featuring no refrigerant, compressors or filters, the 24 VDC and 48 VDC compact coolers are CE and UL recognized. They come prewired with simple terminal block, and are available in 13 models. Pentair Technical Products; www.pentair.com

See Food Master, p. 5-7

52

September 2011 | Food Engineering | www.foodengineeringmag.com

SAVE THE DATE

If leading edge manufacturing and automation technologies are your priorities, save the date for the food industry’s PREMIER CONFERENCE in 2012.

APRIL 22-25, 2012 Sanibel Harbour Marriott, Ft. Myers, Florida

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TECHNOLOGY S O U R C E B O O K

SELF-ALIGNING BEARING UNIT Designed for demanding washdown applications in the food and dairy industries, the Spyraflo aluminum pillow block and housing flange self-aligning bearing unit is manufactured with FDA-approved materials. The pillow block and housing flanges are treated by an electroless nickel plating process; the self-aligning bearings are made of stainless steel. Spyraflo, Inc; www.spyraflo.com

Washdowns without washing out. GROUNDWATER REMEDIATION The Abanaki heavy oil groundwater remediation system does not use a groundwater or torpedo pump; it is equipped with a belt oil skimmer fitted with an ultra-durable poly belt plus stabilizer rods. Capable of removing up to 12gph of high-viscosity oil from water, it can be installed in well casings with a 2-in. inside diameter or greater. The skimmed oil is deposited into a transfer tank. When the tank is full, the removed oil is automatically pumped to a customer-provided collection container. Abanaki Corporation; 800-3587546; www.abanaki.com

IMPACTABLE DOCK DOORS Our flooring is designed to stand up to caustic cleaning agents, tolerates temperatures from -100° F to 220° F and provides the best defense against microbes that can take a bite out of your business. Keep your production line rolling with less maintenance, better compliance and less downtime – choose flooring designed specifically for the food manufacturing industry. For more information, call us or visit our website. Dur-A-Flex, Inc. 95 Goodwin Street East Hartford, CT 06108

800-253-3539 dur-a-flex.com

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September 2011 | Food Engineering | www.foodengineeringmag.com

TKO impactable dock doors are available with a visibility panel that comprises a quarter of the door area or more to allow in sunlight and provide visibility to the outside to monitor truck traffic. The panel consists of a double section of 1/8-in.. thick polycarbonate, bonded to a strong tubular frame. When the vision panel and any other part of the door is hit by a material handling vehicle, the door separates from its guide track to avoid damage to the door, energy loss and possible dock traffic back-ups. TKO Dock Doors; 877-408-6788

Who says you can’t just glide through life? For quality and convenience, choose FiSan E-Z Glide, a revolutionary technology from Chemetall. Specially formulated for the Beverage Industry, FiSan E-Z Glide is a dry film lubricant that is approved for use on Glass, Polycarbonate, and PET bottles. With FiSan E-Z Glide, one lubricant is all you need.

800.526.4473 www.ChemetallAmericas.com

TECHNOLOGY S O U R C E B O O K

DISC PUMPS BACON PACKAGING SYSTEM With a compact footprint to meet the space requirements of most bacon processing facilities, the MULTIVAC R 595 system has the forming station placed within the machine, offering ample area for manual loading. It is also equipped with vacuumassisted loading stations to further define and reinforce the lower package cavities. Product branding and other required package messaging can be delivered using printed top and bottom films, eliminating the need for L-boards and tux cartons. An optional unwinding station for jumbo rolls of film is available. MULTIVAC; www.multivac.com

MECHATRON® 3-A Loss-In-Weight Feeders

Engineered for various continuous dosing applications within the food processing industry, Mouvex Micro C-Series eccentric disc pumps are constructed with a seal-less design that allows the pumps to provide leak-free operation without the need for magnetic couplings or mechanical seals. The pumps are designed for continuous transfer and metering applications, with flow rates from 0.26 to 211 gal./hr. They meet the sanitary requirements of 3A, FDA and European Hygienic Equipment and Design (EHEDG) certification, and have clean-in-place capabilities. Mouvex; www.mouvex.com

Quick, easy product changeover and food safety

SolidsFlow™ USDA Vibratory Feeders

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

www.accuratefeeders.com PLEASE CALL: (800) 558-0184 OR (262) 473-2441 • E-MAIL: [email protected] See Food Master, p. 3

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September 2011 | Food Engineering | www.foodengineeringmag.com

Schenck AccuRate is a unit of Schenck Process

©2009 Schenck AccuRate

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

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

TECHNOLOGY S O U R C E B O O K

VIBRATORY CONVEYOR Performing a variety of product handling and packaging distribution functions, including scale feed applications, the Key Iso-Glide vibratory conveyor is suitable for frozen food processing applications. The conveyor has an independent, frame-mounted drive and spring arm assemblies that distribute energy equally to all parts of the conveyor bed in a controlled, natural-frequency operation to minimize vibration, and enable the conveyor to be installed suspended from overhead, supported from the floor or mounted to other machinery. The speed and stroke can be adjusted to the rate at which product moves to handle a range of products. Key Technology, Inc.; www.key.net

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September 2011 | Food Engineering | www.foodengineeringmag.com

FILLING MACHINES Used over vertical form/fill/seal machines, Hinds Bock SP-64 and SP-160 filling machines feature a long-reach, positive shutoff spout with an adjustable blowoff to maintain a clean seal zone and accurate fills. Models 2P-64 and 3P-32 are used over horizontal vacuum formers; available options for difficult applications include agitated hoppers, diving spouts, traveling spouts and heated or cooled machines. Hinds-Bock Corporation; 877-292-5715; www.hinds-bock.com

TECHNOLOGY S O U R C E B O O K

KVM EXTENDERS Consisting of a small transmitter and receiver unit, Pepperl+Fuchs cULus-listed, Division 2 KVM extenders are rated for use in Class I Division 2 hazardous area applications. Allowing computers and servers to be positioned in a single, centralized location away from environmental hazards, the extenders enable users to send keyboard, video and touch screen or mouse signals over distances up to 1,300 ft. The extenders require no setup, configuration or special software to operate. They are available in 3 versions: VGA to Cat 5, DVI to Cat 5 and DVI to fiber optic. Pepperl+Fuchs, Inc.; 330-486-0002; www.pepperl-fuchs.us

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

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59

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The World’s Top 100 Food & Beverage Companies

Global Power Shifts

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September 2011 | Food Engineering | www.foodengineeringmag.com

` Special Report by Claire Rowan, Managing Editor, Food & Beverage International Magazine

G

rowth in emerging markets is driving activity, despite the need for manufacturers to tackle economic challenges, cut costs, ensure operational efficiency and decrease environmental impact. The world’s leading food and beverage manufacturers are continuing their recessionary tactics and cost-saving exercises along with an increasing drive for international expansion in a bid to capitalize on opportunities for growth in emerging markets, where some have weathered the economic storm better than developed nations. Macro economic drivers are reshaping the face of the industry like never before, with many of the big players now deriving over half of their income from outside their core home markets. In addition, the Top 100 list (see table on page 66) welcomes some new kids on the block from Brazil, China and Japan, which now hold leading positions. “2010 was the last year that the developed world accounted for a higher proportion of our sales than new economies,” says Franck Riboud, CEO of Danone, which entered into a joint venture at the end of last year with Russian dairy Unimilk to create Danone-Unimilk—the number one player in the Russian dairy products market. “In 2010, these economies contributed 39 percent and will automatically pass the 50 percent mark in 2011. In the near term, Russia will move ahead of France and Spain—where we have our roots—and an emerging economy will thus become our largest market.” Danone, which has slipped from its number 12 slot in the listing to 13th place this year, is like all the major players. It is looking to invest in markets with “high growth potential and rapid returns.” China is forecast to become the largest grocery market in the world, overtaking the US in 2012, largely due to the impact of the prolonged US recession and quick recovery in China, according to the latest figures from the Institute of Grocery Distribution (IGD). Russia is following suit with its grocery market predicted to double over the next four years, taking it from the seventh to fourth position globally. India will reach third place in 2015. Brazil current ranks fifth and has overtaken France for the first time this year. “It is not surprising that the BRIC [Brazil, Russia, India, China] countries are forecast to be in the top five global grocery markets. The effect of the global recession on developed markets has accelerated their relative growth, and the pace at which their economies are developing is phenomenal,” says Joanne Denney-Finch, chief executive of IGD. “Many manufacturers have already built a strong presence in these countries, but for those that haven’t, it is vital that they incorporate the BRIC markets into their strategic planning in order to sustain business growth.”

At the top of the list, Nestlé has just partnered with Chinese confectionery company Hsu Fu Chi, which produces sugar confectionery, cereal-based snacks, packaged cakes and the traditional Chinese snack sachima, to reinforce its presence in China. PepsiCo has joined its Mexican bottling forces with the Mexican beverage company GEUPEC (Agrupo Embotelladoras Unidas SAB de CV) and the Venezuelan food and beverage giant Empresas Polar to form a nationwide beverage company in Mexico. In addition, Kraft Foods has just completed a $200 million investment in expanding its manufacturing facilities in Brazil. “Brazil is one of 10 priority developing markets where we’re making big bets,” says Sanjay Khosla, president, Kraft Foods developing markets. “Today, we’re among the fastest growing consumer goods companies in markets like Brazil, India and China. We’re excited to build on what’s working by making our biggest investment in Brazil in more than 10 years.” The company continues to optimize its purchase of Cadbury that it says will bring $750 million in cost synergies, and states that nearly 60 percent of its revenues are now generated outside of the US. (For information about Kraft’s creation of two independent companies, please see page 14.) Yet, in those emerging nations, lead players are themselves tapping into external market opportunities and flouting their economic strength across the globe. Brazilian meat businesses are making significant inroads in the ranking with entrants such as Marfrig joining the list. Fellow Brazilian meat protein company JBS now occupies a compelling sixth place just behind The Coca-Cola Company. Brf Brasil Foods, which was formed by the merger in 2009 between Perdigao and Sadia, sits at number 46. New in at number 29, Marfrig Group was propelled to the top by acquiring companies such as Keystone Foods in the US and Cargill’s animal proteins business Seara Alimentos in Brazil. Its gross revenue of R$17 billion represents a dramatic growth of 65.5 percent since 2009, buoyed by its acquisitions, the strengthening of the Brazilian currency and the increasing demand-over-supply of meat products. Marfrig announced earlier this year that it has now entered into two joint ventures in China through its Keystone Foods subsidiary. Representing an investment in the region of $252 million over 10 years, the joint venture with COFCO provides logistics and distribution services, while the KeystoneChinwhiz Poultry vertical integration joint venture will give Marfrig the capacity to process 200,000 birds per day and supply 50 percent of the raw material for Keystone’s processing unit in the region. “Marfrig has unquestionably become one of the largest and most diversified global food companies,” says Marcus Antonio Molina dos Santos, Marfrig’s chairman, who states the comwww.foodengineeringmag.com | Food Engineering | September 2011

63

TOP 100

PepsiCo Indra K Nooyi, CEO of PepsiCo, believes that in an increasingly global climate, talent management and development should be the number one priority for all CEOs. “If you look at the world between 2007 and now, versus the world that existed in the first part of the decade, the changes are profound,” says Nooyi. “I think the changes are going to be even more disruptive, and they’re going to challenge the best and the brightest.” Talent management might well determine companies’ success or failure, she says.

pany made more than 40 acquisitions in the past four years. JBS has shot to the number 6 slot from 19th position last year. Its international expansion began in 2005 with the acquisition of Swift in Argentina; in 2007 JBS acquired Swift assets in US and Australia, which extended its presence into both the beef and pork sectors. It went on to purchase Smithfield’s beef business, Pilgrim’s Pride to enter the chicken market and Bertin to open up activity in dairy, pet food and biodiesel. JBS now claims to be the world’s largest beef exporter and sells its products in more than 100 countries. JBS says that by diversifying its product offerings, it has added protection against risks in terms of geographic operation and supply of raw materials as well as sector performance and demand. Dairy powerhouses Further demonstrating the influence of emerging economies on the global food and beverage industry coupled with a rocketing growth in dairy activities is the arrival of two more Top 100 newcomers: the Chinese dairies Mengniu and Yili, which entered the Top 100 ranking at number 72 and 88 respectively. “In 2010, China’s rapid and sustained economic growth created favorable conditions for the steady growth of its dairy industry,” says Yang Wenjun, CEO of Mengniu, which has focused on high-end dairy products with launches such as Milk 64

Deluxe Chunxian (a milk product fortified with phytosterol esters and fiber) and the addition of DHA algae to its Future Star Milk. “During the year, Mengniu imposed stringent cost control measures, carried out structural reform and identified new opportunities for business. We successfully acquired Shijazhuang Junlebao Dairy Co., the largest yogurt manufacturer in northern China, and this competitor then became our partner to create synergies in terms of milk sources, markets and channels. Aiming for inclusion among the world’s Top 10 dairy companies and internationalization, the group has formulated a clear business strategy to nurture core competencies.” Fellow Chinese dairy Yili Group shares Mengniu’s goal of entering the world’s Top 10 dairy companies—a goal that was boosted by its activities at the Olympic Games in 2008 and World Expo in 2010 in China. Yili has also turned its focus increasingly to added-value products. Fortified dairy products now account for 40 percent of its total sales. “Dairy is in a real sweet spot, with huge and growing opportunities across Asia, the Middle East and Latin America, a result of a global population growth and trends toward foods with health and nutrition benefits,” says Sir Henry van der Heyden, chairman of Fonterra, the New Zealand dairy company that is soon to welcome new CEO Theo Spierings, who led the Dutch farmer dairy cooperative

September 2011 | Food Engineering | www.foodengineeringmag.com

Royal Friesland Foods in its merger with Campina in 2008. Spierings takes over from Andrew Ferrier who has led Fonterra for the past eight years. Fonterra is up to position 21 from 25 in this year’s ranking. As part of its strategy for growth, Fonterra is actively tapping into international potential with investments in Asia and the Middle East, Latin America and its home markets of Australia and New Zealand. “China is a market that has become increasingly important to Fonterra, and in 2010, it represented our largest single market for ingredients sales,” says Ferrier, who highlighted the reintroduction of the company’s Anlene brand (that supports bone health) in China during the year. Another new dairy entrant at number 52 this year is DMK—the result of a merger between Germany’s two largest milk processing cooperatives, Humana Milchunion and Nordmilch, creating Germany’s largest dairy company. Designed to “secure a leading position as consolidation continues in the European dairy industry,” DMK aims to expand its raw materials base by alliances with strong partners, mergers and acquisitions. “We could envisage processing a milk volume in double-digit billions of kilos within the next two or three years,” says Josef Schwaiger, CEO of DMK. He stresses that as demand for dairy products is stagnating in Germany and the rest of Europe while the supply of milk is growing, DMK’s clear focus will be on expanding its business in non-EU

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Top 100 Food & Beverage Companies Rank

Company

Food Sales ($ millions)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Nestlé PepsiCo, Inc. Kraft Foods Anheuser-Busch InBev The Coca-Cola Company JBS Archer Daniels Midland Company Unilever Mars Tyson Foods SABMiller Cargill Danone Heineken Kirin Brewery Co. Suntory Asahi Breweries Diageo General Mills Inc. Vion Royal FrieslandCampina Kellogg Company Dean Foods Company ConAgra Foods Inc. Fonterra Lactalis Associated British Foods Smithfield Foods Inc. Marfrig Group Ajinomoto Carlsberg HJ Heinz Company Nippon Meat Packers Pernod Ricard Yamazaki Baking Meiji Holdings Grupo Bimbo (Mexico) Ferrero Femsa Arla Foods Sara Lee Corporation Sudzucker Maruha Nichiro Holdings Bunge Danish Crown Brf Brasil Foods Campbell Soup Company Hormel Foods Corporation Kerry Group Dole Food Company, Inc.

99,733 57,838 49,207 36,297 35,119 31,285 31,000 30,160 30,000 28,430 28,311 26,000 22,530 21,370 19,545 17,772 15,880 15,258 14,797 12,565 12,470 12,397 12,123 12,079 12,035 11,805 11,600 11,203 11,071 11,025 10,685 10,495 10,190 9,845 9,415 9,336 9,280 9,175 8,910 8,725 8,667 8,565 8,558 8,388 8,045 7,850 7,676 7,221 6,895 6,893

Year Ending Dec. 10 Dec. 10 Dec. 10 Dec. 10 Dec. 10 Dec. 10 Jun. 10 Dec. 10 Dec. 08 Sep. 10 Mar. 11 May 10 Dec. 10 Dec. 10 Dec. 10 Dec. 10 Dec. 10 Jun. 10 May 10 Dec. 09 Dec. 10 Dec. 10 Dec. 10 May 10 Jul. 10 Dec. 09 Sep. 10 Apr. 10 Dec. 10 Mar. 10 Dec. 10 Apr. 10 Mar. 10 Jun. 10 Dec. 10 Mar. 10 Dec. 10 Aug. 10 Dec. 10 Dec. 10 Jun. 10 Feb. 11 Mar. 10 Dec. 10 Sep. 10 Dec. 09 Aug. 10 Oct. 10 Dec. 10 Dec. 10

Source: Global Food Markets (GFM), Leatherhead Food Research.

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September 2011 | Food Engineering | www.foodengineeringmag.com

Rank 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

Company

Food Sales ($ millions)

Grupo Modelo (Mexico) DMK Deutsches Milchkontor CHS Inc. Morinaga Milk Industry Oetker Group Parmalat Barilla McCain Foods Ltd The Hershey Company Dr Pepper Snapple Group Tate & Lyle Bacardi Saputo Barry Callebaut Red Bull Bongrain Nippon Suisan Kaisha Itoham Foods Maple Leaf Foods The JM Smucker Company LVMH China Mengniu Dairy Company Tchibo Corn Products International Nisshin Seifun Group Japan Tobacco International Schreiber Foods Ralcorp Holdings Premier Foods Nissin Food Products QP Corporation Fosters Group Del Monte Foods Company Sapporo Holdings Land O’ Lakes Inc. CSM Glanbia Yili Group Ito En Sodiaal Coca-Cola Amatil Muller Group Groupe Bel McCormick & Company Constellation Brands Molson Coors Brewing Company Chiquita Brands International Brown-Forman Corporation The Procter & Gamble Company Ebro Foods

6,730 6,670 6,575 6,255 6,050 5,978 5,800 5,700 5,671 5,636 5,470 5,336 5,098 5,015 4,990 4,962 4,922 4,835 4,630 4,605 4,533 4,470 4,390 4,367 4,310 4,215 4,100 4,049 4,005 3,965 3,930 3,896 3,740 3,725 3,708 3,600 3,582 3,575 3,560 3,455 3,415 3,380 3,361 3,337 3,332 3,254 3,227 3,226 3,135 3,055

Year Ending Dec. 10 Dec. 09 Aug. 10 Mar. 10 Dec. 09 Dec. 10 Dec. 09 Jun. 09 Dec. 10 Dec. 10 Mar. 10 Mar. 09 Mar. 10 Aug. 10 Dec. 10 Dec. 10 Mar. 10 Mar. 10 Dec. 10 Apr. 10 Dec. 10 Dec. 10 Dec. 09 Dec. 10 Mar. 10 Mar. 10 Sep. 09 Sep. 10 Dec. 10 Mar. 10 Nov. 10 Jun. 10 Apr. 10 Dec. 10 Dec. 10 Dec. 10 Dec. 10 Dec. 09 Apr. 10 Dec. 09 Dec. 09 Dec. 08 Dec. 10 Nov. 10 Feb. 11 Dec. 10 Dec. 10 Apr. 10 Jun. 10 Dec. 09

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TOP 100

Mengniu As a newcomer to the Top 100 list, Mengniu demonstrates the influence of emerging economies on the global food and beverage industry coupled with a rocketing growth in dairy activities. According to Mengniu CEO Yang Wenjun, “In 2010, China’s rapid and sustained economic growth created favorable conditions for the steady growth of its dairy industry.” The company has focused on high-end dairy products with launches such as Milk Deluxe Chunxian (a milk product fortified with phytosterol esters and fiber) and the addition of DHA algae to its Future Star Milk.

countries. It intends to set up a branch office in China by the end of the year. “A lot of countries will not be in a position to cover domestic demand from their own milk production in the medium term,” says Schwaiger. “In the interests of our milk producers, we don’t want to leave these markets to our competitors.” Challenges and opportunities The increasing globalization of all players, coupled with the backdrop of raw material price volatility, an uncertain economic future and growing environmental concern, is bringing new pressures, challenges and opportunities for all players. “It would be no exaggeration to say that this has been a decade of turmoil for Japan’s

economy and society. In addition to our long recession, the pace of economic globalization is accelerating. Industries are forced to compete fiercely, not just with developed countries but with emerging economies as well,” says Nobutada Saji, chairman of the board of Suntory Holdings, which is up from 18 to 16 in the ranking this year. “Japan, and indeed the world, is entering a time of great change, in which conventional values no longer hold.” According to Saji, the activities of the individual companies will continue to be rooted in Suntory Group’s corporate philosophy, “In Harmony with People and Nature,” which pursues a sustainable coexistence between the global environment and human society.

Changing global balance “This new balance [toward emerging markets] changes the shape of the Danone group and brings new challenges, in particular in the field of human resources— starting with recruitment, training and the deployment of Danone’s fundamental principles among more than 100,000 staff members,” says Riboud. “Until recently, we assumed the richest countries would be the main source of innovation. As I see it, it’s the countries with strong growth that should inspire us especially as we have to deal with an economic downturn, resource shortages and a squeeze on consumer purchasing power. “The strength of emerging-economy businesses is that they have faced that

Marfrig New in at number 29 on the Top 100 list, Marfrig Group was propelled to the top by acquiring Keystone Foods and Cargill’s animal proteins business, Seara Alimentos in Brazil. Its gross revenue of R$17 billion represents a dramatic growth of 65.5 percent since 2009, buoyed by its acquisitions, the strengthening of the Brazilian currency and the increasing demand-over-supply of meat products. “Marfrig has unquestionably become one of the largest and most diversified global food companies,” says Marcus Antonio Molina dos Santos, chairman of Marfrig.

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September 2011 | Food Engineering | www.foodengineeringmag.com

TOP 100

Coca-Cola Muhtar Kent, CEO of The Coca-Cola Company, thinks it is important for leaders of global companies to be well versed in international affairs, and to have had a breadth of experience living and working in markets around the world. “To me, it is about putting all our decisions and actions through a global filter. For instance, how would a decision made for our business in the US impact our business in India? How would this innovation in Poland transfer to market in North America? It’s about critical thinking and cross-cultural understanding.”

sort of thing for a long time and have come up with simple, economical and very inventive solutions,” adds Riboud. “Building a micro-dairy product plant in Bangladesh with the sort of budget you’d have for a house in France forced us to adopt radically new solutions,

70

some of which can be applied perfectly in our big, traditional plants without compromising quality.” Muhtar Kent, CEO of The Coca-Cola Company, which has 80 percent of its business coming from outside the US, stresses that it is important for leaders of

September 2011 | Food Engineering | www.foodengineeringmag.com

today’s global companies to be well versed in international affairs, and to have had a breadth of experience living and working in markets around the world. “To me, it is about putting all our decisions and actions through a global filter. For instance, how would a decision made

Danone “2010 was the last year the developed world accounted for a higher proportion of our sales than new economies,” says Franck Riboud, CEO of Danone, which entered into a joint venture at the end of last year with the Russian dairy Unimilk to create Danone-Unimilk—the number one player in the Russian dairy products market. “In the near term, Russia will move ahead of France and Spain—where we have our roots—and an emerging economy will thus become our largest market.” Photo by Mélanie Frey

for our business in the US impact our business in India? What can we learn from our experiences in Mexico that might apply to China? It’s about critical thinking and cross-cultural understanding.” With these changes taking place in the world, Indra K Nooyi, PepsiCo’s CEO,

believes an increasingly global context, talent management and development should be the number one priority for all CEOs. “If you look at the world between 2007 and now, versus the world that existed in the first part of the decade, the changes are profound,” says Nooyi. “And,

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

71

TOP 100

DMK In at number 52 this year, DMK is the result of the merger between Germany’s two largest milk processing cooperatives, Humana Milchunion and Nordmilch, creating Germany’s largest dairy company. Designed to “secure a leading position as consolidation continues in the European dairy industry,” DMK aims to expand its raw materials base by alliances with strong partners, mergers and acquisitions. “A lot of countries will not be in a position to cover domestic demand from their own milk production in the medium term,” says Josef Schwaiger, CEO of DMK. “In the interests of our milk producers, we don’t want to leave these markets to our competitors.”

“In technical areas globally, a tremendous talent shortage is looming, so we have really to think about what that means for companies and how you think about staffing R&D departments in particular.”

PepsiCo has actively established extensive succession planning and employee engagement and recruitment policies to retain and foster its workforce and take the company and its employees into the future. Engagement of both employees

and consumers underpins PepsiCo’s activities, as it does those of other leading players. This engagement on a global scale and the agility to respond to the prevailing macro trends will determine the Top 100 rankings in the years to come. ❖

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September 2011 | Food Engineering | www.foodengineeringmag.com

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CONTINUOUS IMPROVEMENT `Manufacturing professionals increasingly are turning to lean manufacturing experts for training in continuous improvement methodologies. Source: Lean Learning Center.

Performance tools move manufacturing forward Altering processes and procedures requires human involvement, but that doesn’t preclude technical support for continuous improvement efforts. ` Kevin T. Higgins, Senior Editor

J

ohn Henry famously lost his fight against a machine. To make any machine run better, though, requires the help of people like John. As manufacturing organizations struggle with downward pricing pressures and rising raw-material costs, the need grows to eliminate waste and squeeze better performance out of existing assets. Efficiency improvements always were desirable, but today’s operating environment raises continuous improvement to cult status. Unlike food manufacturers of the past, however, today’s profes-

sionals are better organized, more disciplined and better trained in applying the analytical techniques that drive the Shewhart cycle: Plan, do, check, act. The cycle’s namesake, Walter A. Shewhart, developed it in the 1920s while working as a Western Electric engineer. Failure rates and necessary repairs of buried telecommunications equipment were unacceptably high. An alternative to finished goods inspection was needed, and Dr. Shewhart developed a methodology that shifted manufacturers from reactive solutions to a focus on uncontrolled

www.foodengineeringmag.com | Food Engineering | September 2011

75

CONTINUOUS IMPROVEMENT engaged and reporting problems instead of hiding them” underpins the approach, says Hamilton, whose nom de blog is Old Lean Dude. GBMP concentrates its outreach on manufacturers, hospitals and other industries in the Northeast, though major Midwestern ice cream and frozen food companies send contingents to New England to help shape their wasteslashing programs.

` Optimizing process flow with an eye toward eliminating waste is a basic tenet of lean manufacturing, though proponents sometimes disagree on the appropriateness of conveying systems.

76

process variation. The simplified expression of this approach was the first control chart. Dr. Shewhart introduced new concepts in statistical modeling that now are being applied with a vengeance in food and beverage production. Improvement is a big tent, and some uneasy alliances can occur when users of different approaches toward a common goal are thrown together. The obvious examples are lean manufacturing proponents, with their bottom-up philosophy, and Six Sigma. Noting both approaches derive from the same base (Shewhart disciple W. Edwards Deming), lean consultant Bruce Hamilton believes each is a valuable tool for continuous improvement, along with information technology such as MES and SPC programs. But the president of the Greater Boston Manufacturing Partnership (GBMP) emphasizes that people drive improvement, not the tools themselves. The ideas underlining Six Sigma “are very important,” he allows, but the formality surrounding it contributes nothing. Of the belt hierarchy, Hamilton sniffs, “That’s consultants making money by giving somebody a diploma.” A nonprofit corporation based at University of Massachusetts in Boston, GBMP is an American iteration of the Toyota production system. Waste reduction is the goal, “and getting employees

September 2011 | Food Engineering | www.foodengineeringmag.com

Get on the improvement train The food industry may trail automotive and electronics in adopting disciplined, organized approaches to quality improvement and waste reduction, but it’s ahead of hospitals, Hamilton says. “Until recently, they were in total denial,” he says, a disturbing situation, given the consequences of poor quality and procedural deviation. While lean derides technology when it is applied inappropriately, food companies could learn from their technology suppliers, many of which have taken the Toyota system and adopted it to their own efforts. An example is the Bosch production system (BPS), which melds lean, Six Sigma, Shanin and “old-fashioned engineering troubleshooting, but it’s systematic now,” according to Jerry Devall, director of quality-Americas at Bosch Rexroth Corp., Fountain Inn, SC. He describes Shanin as complex, event-specific improvements that are “a BOB and a WOW,” shorthand for an attempt to identify the best of best and worst of worst current practices. Metrics such as overall equipment efficiency (OEE) are useful starting points for fully automated processes, says Devall, but when manual operations are part of the mix, “OEE is not a good indicator” of improvement. In organizations with diverse business units and global production networks, key performance indicators (KPIs) set by top management are a better gauge of progress toward specific goals. All of the 16 Bosch facilities throughout the Americas to which Devall provides technical support are audited and scored

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CONTINUOUS IMPROVEMENT annually for their progress in meeting their goal. When the goal is surpassed, that facility’s best practices are dissected and applied throughout the network. BPS guides improvement efforts for daily operating procedures, with Six Sigma black belts and Shanin practitioners stepping in when managers see a need to “call in the cavalry,” he explains. Improvement objectives necessarily change as customer expectations shift. Logistics has joined scrap reduction and other traditional KPIs because “the customer wants the right product at the right time, with the proper paperwork,” says Devall. Prioritizing projects and attacking them systematically is the biggest change he has witnessed in a quarter-century of quality improvement work. Before Bosch acquired Rexroth in 2000, “we had 106 projects going on in our facility, all competing for the same resources,” he says. Now the staff focuses on the top 10 until problems are resolved and do not recur. Peaceful coexistence of 5S, statistical analysis programs, Six Sigma and lean within an organization is more the rule than the exception, suggests lean trainer Andy Carlini, a partner at the Lean Learning Center, Novi, MI. Problems arise when an organization becomes enamored with one methodology and

apply it inappropriately. “It becomes a case of tool first, opportunity second, and it should be the other way around,” he says. Data interpretation demands specialized skills and is absolutely necessary in some cases, but “if you make it analytical, the chances of engaging people throughout the organization are slim,” says Carlini. If improvement is to be continuous, cultural thinking must change, and easily attainable improvements need to be made to involve the entire staff in the effort. Improvement culture club Whether an organization takes a bottom-up approach to improvement or relies on subject matter experts, an effective program requires a work culture that encourages a continuous effort. The second imperative is an effective measurement system. It can be based on automated data collection or clipboard entries, believes Steven Hawkins, director of automation services at Jacksonville, FL-based Stellar, but data accuracy is absolutely critical. Referring to MES and other data-reporting software, Hawkins says, “You don’t necessarily have to have a highperformance Ferrari to implement continuous improvement.” But if the initiative requires internal resources to sustain itself,

Visual factory management The beauty of a concept like continuous improvement is that it is broad enough for everyone to put their own twist on it. Lean manufacturing gurus and vendors of automation software have staked their claims to continuous improvement, but many other suppliers are adding their take, including industrial suppliers. Lake Forest, IL-based W.W. Grainger Inc. has been deploying segment managers to industrial sites to get a firmer grip on customer needs. Based on his visits to food plants, food & beverage specialist David Strzyzynski recognized the high premium on food safety. To help provide some solutions, the company developed a catalog of more than 7,000 food safety products, many of them NSF certified, FDA/USDA compliant or food-grade rated. Strzyzynski also was struck by food companies’ embrace of lean manufacturing and continuous improvement, which led to a family of products grouped around the concept of visual factory management. One element is the 5S board, also known as a quality board, he explains. At a large food plant he visited, Strzyzynski noticed that tools and equipment for sanitary washdown were strewn about. Applying the 5S workplace organization philosophy, he devised the 5S shadow board as a way to help sort, set in order, shine, standardize and sustain orderly

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September 2011 | Food Engineering | www.foodengineeringmag.com

` Customized 5S shadow boards are complementary tools for visual factory management, a component of lean programs. Source: W.W. Grainger Inc.

placement of those tools. It’s a simple concept: The outlines of the tools themselves are on the board; if the space is blank, the item either is in use or out of place. “As with any continuous improvement effort, it has to be adopted by the employees to be useful,” he points out. By making the process easy to use and providing basic training, companies can gain worker buy-in to this element of the pursuit of waste elimination, says Strzyzynski.

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CONTINUOUS IMPROVEMENT upfront guidance is essential until personnel are comfortable with the methodology. When building the team, Hawkins defers to the two-pizza rule: “If it takes more than two pizzas to feed the team, it’s too big.” Statistician John Surak takes a more expansive view, arguing quality improvements occur over a long period and require involvement throughout the shop floor. Six Sigma black belts, on the other hand, excel at experimental designs. “The other way to approach improvement is to look at data over time, which was Shewhart’s position,” says Surak, a fellow of the American Society for Quality, the Milwaukee association founded by Dr. Shewhart. If the process is stable, the longterm effects of improvement can be measured. If problemsolving requires experimental design, it’s time to call out the black belts. “Those are two very different approaches to problem solving with statistics, and each requires a completely different set of questions,” he says. The analytical tools behind a plant’s control charts often require expertise that may be absent, Surak adds, but statistical process control packages like Northwest Analytics’ (NWA) quality analysis render the issue moot. “The statistical programs to do the analysis are already in there,” he says. But there are no plug-and-play solutions to continuous improvement, cautions Wendy Armel, senior MES analyst with Stone Technologies Inc., Chesterfield, MO. “Software only gives you

the information,” the systems integrator says. “You have to interpret it and make the appropriate changes to implement.” Speaking at an NWA webinar on using SPC and OEE to effect packaging line improvement, Armel emphasized the need to deliver real-time information to the production floor. Immediacy is only part of the reason: Real-time data removes human intervention and misinterpretation and allows the staff to react to facts on the ground. It also allows operators to respond to throughput issues, rather than providing data input. Once data-collection software is selected, it must be implemented and supported. Failure to maintain the system can cause the improvement initiative to stall. Even before implementation, however, comes workforce engagement. “The starting point often is cultural change,” says Armel. Infinity QS International’s Jennie O’Neal agrees, saying, “Software is just a component of quality improvement.” Whether data indicates process drift or provides an event alarm, buy-in from the entire staff is a prerequisite to information technology’s effectiveness. The quality improvement system Infinity installed at Shearer’s Foods in Brewster, OH relies in part on video monitors prominently placed throughout the plant to provide a real-time stream of production information to alert personnel of production disruptions. “The information

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September 2011 | Food Engineering | www.foodengineeringmag.com

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CONTINUOUS IMPROVEMENT Gap analysis of OEE erosion factors Equipment failure Operational downtime Shutdown Process failure

Best in class 5.97%

Laggards 15.88%

2.71%

7.18%

2.1%

7.05%

1.96%

7.31%

pricing trend, notes Mike Wilder, marketing and strategic liaison at MES provider Seeit Solutions LLC, Schaumburg, IL. “No one is going to spend $100,000 for flatscreen displays, which is what they would have cost four or five years ago to hang throughout the plant,” says Wilder. With prices plummeting, the technology has become an affordable tool of continuous improvement.

Survival mode Technology in and of itself won’t improve Unspecified downtime 2.03% 12.58% manufacturing operations, tech providers readily admit. Information technology in Source: 2009 Informance Benchmark Study. particular must be in synch with the people who will use it, or else it will have an adverse needs to be visual, and it must be provided when an event affect. “If you put in sophisticated technology but it’s not is generated so that staff can react quickly and properly,” complemented by effective business practices, the business says O’Neal. Process monitors map the equipment on the will actually take a step backward in terms of performance,” floor, and color changes from green to red draw people’s maintains John Oskin, executive vice president of Solareyes to the monitor. “The data are the only voice the prosoft, a Northbrook, IL-based MES supplier. A functioning cess has,” she points out, but unless the staff is listening, improvement program and an engaged staff are prerequithe voice is not heard. sites to automated data collection and analysis. Video displays of KPIs and OEE metrics were a manufacturAs a founder of Informance International, which was ing rarity until the monitors followed electronics’ downward acquired last year by Solarsoft, Oskin benchmarks manuChangeover

1.04%

4.41%

See Food Master, p. 48

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September 2011 | Food Engineering | www.foodengineeringmag.com

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CONTINUOUS IMPROVEMENT facturing efficiency in various industries, including food and beverage. In a recent report, based on OEE measurements for 725 food and beverage lines, he categorized the top quartile of performers as best in class, the bottom quartile as laggards and the 50 percent in the middle as average. Technology delivers the same data to all three groups. Top performers respond better to the information because they have a continuous improvement culture in place and are able to analyze and interpret the information provided. The impact can be huge. Equipment failures rob laggards of almost 16 percent of potential production, for example, while best-in-class lines lose less than 6 percent of potential OEE to equipment failure (see chart on page 82). “Practices and systems must be aligned,” says Oskin, and if personnel practices are not able to leverage what the system provides, technology will fail. Pricing pressures, tighter margins and rising raw-material costs frequently are cited to explain the industry’s embrace of lean and related programs, but macro economic forces also are at play. North American manufacturers no longer compete with the plant down the street; they must provide a compelling rationale for retaining onshore production. As head of GBMP, Hamilton serves as a manufacturing advocate, and he is cognizant of the pressures at work. He

notes the case of a nonfood manufacturer that began offshoring the final step in its production cycle, loading work in process into containers and bringing back finished goods. “That’s what we’re fighting: the cost accounting model,” sighs Hamilton. Among his six rules for staying young, baseball legend Leroy “Satchel” Paige advised, “Don’t look back—something might be gaining on you.” Food manufacturers would do well to take those words to heart. Processes and personnel either are improving or deteriorating. Continuous improvement is today’s survival mode. ❖ For more information: Jerry Devall, Bosch Rexroth Corp., 864-228-3023, [email protected] Bruce Hamilton, Greater Boston Manufacturing Partnership, 617-287-7729 David Strzyzynski, W.W. Grainger Inc., 847-535-1000, [email protected] Jennie O’Neal, Infinity QS, 703-961-0200, [email protected] Andy Carlini, Lean Learning Center, [email protected] Mike Wilder, Seeit Solutions LLC, 847-483-8703, [email protected] John Oskin, Solarsoft, 847-498-1844, [email protected] Steven Hawkins, Stellar, 904-899-9398 Wendy Armel, Stone Technologies Inc., 972-395-1627 John Surak, Surak & Associates, 864-506-2190, [email protected]

Haskell is an acknowledged industry leader in the design and construction of world class manufacturing facilities for the food and beverage industry. As the nation’s leader in sustainable design and construction, Haskell builds energy efficient facilities for top 50 companies in the industry and has long been known for its innovation in design and efficiency in project execution.

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See Food Master, p. 67

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September 2011 | Food Engineering | www.foodengineeringmag.com

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26TH ANNUAL PACKAGING TRENDS STUDY

Priorities reconsidered Speed always is a priority in packaging operations, but market realities are elevating other considerations for food and beverage professionals. ` Kevin T. Higgins, Senior Editor

S

crambling to keep up with production, bonuses based on total throughput, dealing with line hiccups: Those were the good old days in food and beverage packaging. Today’s supervisors, engineers and other packaging professionals have a lot more on their plate as they cope with the sometimes contradictory demands of customers, the supply chain and senior management. Based on reader feedback to Food Engineering’s packaging trends survey, today’s pressures are forcing a reshuffling of priorities and a renewed focus on changes designed to improve overall performance. An example of the shift in priorities is the ratings of 17 issues and their impact on packaging operations in the next two years. Product safety consistently has ranked second over the years, but the gap between safety and material costs is widening, with barely half the readers believing safety will have a big

or great impact, with a comparable number judging machine flexibility and changeover speed to be a big-impact issue. By comparison, 71 percent say material costs will have a big impact. Asked what actions their companies are pursuing to boost equipment availability, three in five survey respondents cite greater operator involvement in routine maintenance. The second most popular strategy is greater OEM involvement in maintenance training, though only 22 percent are taking that approach. Additional equipmentavailability initiatives with similar support are training and education by outside experts and expanded maintenance staffing. Readers volunteer ISO 9000:2008 certification and “implementation of TPM pillars—skills development, focused improvement, autonomous and preventative maintenance, vertical startup, loss analytics, etc.” as elements of improved availability.

www.foodengineeringmag.com | Food Engineering | September 2011

87

PACKAGING TRENDS SURVEY Top issues impacting packaging operations (ratio of respondents rating it very/extremely important; multiple responses permitted) Material costs

72%

Product safety

54%

Increased flexibility/changeover speed

48%

Track & trace requirements

47%

Product shelf life

43%

Sustainability concerns

41%

Consumer convenience

40%

Source: Food Engineering’s 2011 Food Packaging Trends Survey.

Overall equipment efficiency is the metric of choice for evaluating machine performance, not only in production but packaging, as well. Almost half (48 percent) of readers say OEE is driving continuous improvement in packaging. One in five cites increased reliability, and one in 10 focuses on faster changeovers. Improved maintenance procedures are being sought by 8 percent, and another 7 percent are zeroing in on reductions in product giveaway. Hygienic machine design is a priority throughout today’s food plants, and it’s not surprising that one in four (27 percent) of respondents specifies better hygienic design as the primary area for needed improvement in packaging equipment. Slightly more (28 percent) want equipment that can handle a broader range of container sizes and shapes. Simplified programming (19 percent) and more heavy-duty construction (16 percent) are other

needs. Despite the interest in requiring operators to shoulder a bigger share of maintenance responsibilities, only one in 25 readers feels operator safety is an area that needs improvement.

Unclogging chokepoints Respondents were asked to identify the biggest bottleneck in their packaging line and to indicate the likelihood it would be cleared in the next year. Unsurprisingly, filling operations are the most frequently cited chokepoint, and 14 readers say their organizations are very or somewhat likely to take corrective action. Eight others say their firms are unlikely to fix the problem, including three who indicate action is very unlikely. Palletizing is the next most frequently mentioned bottleneck. Seven readers say corrective action is likely, compared to six who say a fix is unlikely. Case packing, sealing and erection follow, with three saying improvements are very likely, and two who rate corrective action as somewhat likely. Two believe a change is somewhat unlikely, and one reader holds scant hope for improvement. Accumulation systems, labeling operations and capping and sealing are cited as bottlenecks by numerous respondents. Three readers mention slicing. “The slicing area slows us down considerably, before we can get into the boxing of products,” one reader writes. “Cereal bar chokepoint is at the cutting table guillotine, ahead of the in-line wrappers,” writes another. Both indicate improvements are somewhat likely. As previously noted, material costs, product safety and increased flexibility/changeover speed rank as the top three issues facing packaging operations over the next two years. Little has changed in the rankings of 14 other factors over the

Who answered the survey? Statistics and industry feedback to the 26th annual Food Packaging Trends survey were gleaned from 147 responses to a Web-based questionnaire. Greater diversity in employment responsibilities is reflected, with 28 percent of the sample responsible for engineering and 20 percent charged with operations or production management. Administrators and general management represent another 17 percent, while the proportion of R&D professionals has increased to 8 percent. The largest change is in QA/ QC respondents, which doubled to 10 percent. Purchasing, maintenance, logistics planners and owners and CEOs also provided input. Survey participants represent food and beverage plants that are slightly smaller than last year’s sample and notice-

88

September 2011 | Food Engineering | www.foodengineeringmag.com

ably smaller than in 2009’s survey. The majority work at sites with fewer than 100 workers and smaller budgets, with 56 percent spending less than $100,000 on new packaging equipment and 53 percent spending less than $500,000 on packaging materials. By comparison, three in five answering the 2009 survey had material budgets exceeding $500,000. A diversified manufacturing base is reflected, with processed meat, poultry and seafood products representing the largest segment at 17 percent. Other well-represented categories are beverages (14 percent), supplements and ingredients (12 percent), baking and snack foods (10 percent) and dairy/frozen novelties and cereal/grain-based products (each 8 percent).

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PACKAGING TRENDS SURVEY tenance is called on [to make] quick fixes that operations is responsible for.” Material waste is an area several readers would like to see their organizations tackle. Waste reduction programs often are cast as 2011 elements of sustainable manufacturing, though 43% they just as easily could be considered an out29% come of lean manufacturing and efficiency initiatives. A question on sustainable practices 27% was recast this year as efficiency practices, and 27% half the respondents indicate their companies 18% have taken action to reduce waste streams, the 16% same proportion as a year ago. Efforts to reduce energy use are underway at three out of five 12% plants, making it the most common efficiency effort. Efforts to reduce transportation costs and cut back on the amount of material used for secondary packaging grew in popularity. Pressure is building to slash supply-chain costs, and two out of five readers say their organizations redesigned primary packages or shipping materials to drive down costs. “We streamlined our packages and eliminated smaller, less profitable items and tried to increase our throughput and lower man-hour costs per lb.” of finished goods, a packaging professional writes. “Tracking of all waste material to reduce any losses” is another firm’s tactic. Others cite conversions to smaller carton sizes, reductions in the size and weight of primary and secondary packaging, less stretch wrap, thinner gauges of film, substitution of bag-inbox for rigid containers and a host of other tactics. The most frequently mentioned effort, however, is forging relationships with new suppliers. “More supply chain competition,” one writes, “by searching for more suppliers.”

Packaging department’s to-do list (multiple responses permitted) 2010 Adapt line for multi-package handling

57%

Install new lines

42%

Reduce capital projects

24%

Increase capital projects

27%

Create strategic alliances

19%

Purchase secondary packaging equip.

26%

Outsource to copackers

22%

Source: Food Engineering’s 2011 Food Packaging Trends Survey.

last three years, with two exceptions: Consumer convenience has plunged to the seventh rated issue, down from No. 3 in 2008, while faster line speeds rank eighth, down four slots since 2010. Given a general shift from mass-produced products to greater customization, the growing importance of flexibility and a de-emphasis on raw speed are two sides of the same coin. A connection also can be found in responses to the question, “Where does your company’s packaging effort fall short?” More automation is the prevailing need, but barriers to implementation go beyond financial considerations. Several readers cite lack of space as an impediment to additional equipment. “Room in the plant for additional equipment is very short,” writes one respondent. The versatility vs. high-speed trade-off resurfaced in another written comment: “Automation with more flexibility [is the shortfall]. The big concern is, when you automate, you give up flexibility. We fall short in both catego- Leave well enough alone ries at the moment.” Not everyone is sold on the need for changing materials, packagBenefits often classified as soft paybacks are cited by one ing systems or suppliers, of course. In fact, slightly more than half reader as a justification for committing capital to address a specific say their firms have stuck with the tried and true in recent years. automation shortfall. “We could improve costs and product qual- The cost of change and existing equipment investments are the ity, reduce consumer complaints and possibly reduce overfill by primary reasons for standing pat, but one quarter of the sample replacing some manual pick-and-place efforts How companies boost equipment availability w ith more reliable (multiple responses permitted) vision-controlled pickand-place robotics,” this Operator-driven routine maintenance 58% individual notes. OEM maintenance training 22% Changeovers, mainThird-party training & education tenance and opera18% tor training are other 17% Expanded maintenance staff frequently cited 9% Recruitment of equipment experts shortfalls. “ We need 7% Online training better-trained opera0 10 20 30 40 50 60 tors to step up to the plate,” a packaging proSource: Food Engineering’s 2011 Food Packaging Trends Survey. fessional writes. “Main90

September 2011 | Food Engineering | www.foodengineeringmag.com

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PACKAGING TRENDS SURVEY product to market. Existing-equipment modification was the most popular tactic to speed market entry, with two in five taking that route. More automation and the addition of modular lines also 4% were cited. Only one in eight turned to Greater container-handling range 28% 7% a contract packaging firm, down from Better hygienic design 26.5% one in five in last year’s study. 28% Compared to last year’s study, this 15.5% Simplified programming 19% year’s respondents are less apt to implement supply-chain programs to reduce More robust construction 15.5% damage in transit, monitor shipment 19% 26.5% Remote diagnostics capability 7% locations or control the distribution process better. The one area where there Improved operator safety 4% was an uptick in activity was temperature monitoring of shipments, with one in four indicating a system was in place. Source: Food Engineering’s 2011 Food Packaging Trends Survey. Similarly, the proportion of readers focusing on projects such as adapting cites uncertainty about how customers would react to change as lines to handle different package types, installing new lines and the reason they haven’t taken any action. “Overwhelming number investing in material-handling equipment is static or declining, of customers prefer to leave our packaging as is,” one reader com- compared to last year. The lone exception is an increase in firms who are reducing expenditures for capital projects: 27 percent ments. Several indicate there simply is no need to change. Change is easier to rationalize if it serves a business objec- say spending will be down this year, identical to the number tive such as decreasing the amount of time needed to get a new who say they will increase capital spending. ❖

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T E C H U P D AT E : ROBOTICS Wayne Labs, Senior Technical Editor

` For pick-andplace applications, delta-style robots can make up to 140 or more picks per minute, depending on product and application. Source: Bosch Packaging.

All the right reasons for robots

`

After they’ve proved their worth in secondary packaging and grunt applications, robots are slowly making inroads for jobs closer to the process.

A

sk any robot supplier or system integrator whether it’s a good idea to choose robots because you’d like to replace a couple of dozen humans—or take on a complicated task that hasn’t been automated before—and the experts will be the first to say, “Let’s take a very careful look before we continue with this project.” While robots have had an excellent track record in general manufacturing, putting them to work in a food or beverage plant puts additional demands on them and the processors who maintain them. But there are benefits. Besides performing in heavy lifting and pick-and-place applications, robots and controllers combined with smart vision systems

can spot damaged product and keep track of lot and serial numbers when required. And they provide new solutions in traditional, mature applications. According to Brian Huse, director of marketing for the Robotics Industry Association, robotic systems currently can be used in handling bags, flow packing and packaging/kitting and palletizing and depalletizing applications. With the recent availability of delta-style robots, mid-stream process applications are beginning to employ robots for stacking and assembling food parts, for example, cookies. While most processors find the consistency of robotic/vision systems helps eliminate product waste and improves quality, too “perfect” may not

www.foodengineeringmag.com | Food Engineering | September 2011

95

T E C H U P DAT E both flexibility and speed, because it is a pick-and-place system and not a dedicated, hard-engineered system. “We can pick-and-place nearly anything, which gives us tremendous flexibility to deliver customized product solutions for existing and future customers,” adds Wolfgang. The processor produces more than 120 SKUs on 14 lines, and added 40 employees to its workforce the same season Lucy and Ethel began work.

` “Hired” in 2009, Lucy and Ethel—two ABB FlexPicker deltastyle robots—work untiringly picking candies and arranging them for packaging. The right-hand photo captures a wider view of the line. Source: Wolfgang Candy Inc.

always be desirable. Huse points to a Pepperidge Farm application where delta robots assemble cookies. To keep a handmade appearance, the robots are actually programmed to be a bit imperfect in the cookies they build. As a processor looks further upstream toward processing, applications tend to get more complex and are sometimes tricky to implement. “In terms of the level of automation, secondary packaging is more mature [than primary packaging], mainly because the complexity to handle primary packed products is [less] than that of ‘naked’ products, which are mainly picked and placed,” says Roland Czuday, Bosch Packaging Systems product manager. Challenges often occur in the design of the gripper to ensure safe and gentle product handling, he adds. Ostensibly, according to Czuday, it comes down to building into an automation system the positive attributes of human beings at a competitive price. These attributes are what we take for granted: keen eyesight, manual dexterity, quick thinking and flexibility to adapt—which translate to real-time vision systems, multi-purpose gripping tools, easyto-program and reliable controllers and the ability of software to adapt to product changes. Flex ibility and speed are why Wolfgang Candy (a 100,000-sq.-ft., three-building operation in York, PA) hired “Lucy and Ethel,” two ABB Model IRB 340 FlexPicker robots, to automate a new primary packaging line for its chocolate candies. Installed by JLS Automation in 2009, the robots meet the processor’s increased production needs for contract and private-label production. Rob Wolfgang III, food safety and quality manager, is enthusiastic about the customizable potential offered by the new line. “Another expectation for the robot,” says Wolfgang, “was speed.” We needed a system that could meet or exceed 200 pieces per minute. JLS has given us 96

September 2011 | Food Engineering | www.foodengineeringmag.com

New solutions in mature applications While it may seem that secondary packaging applications are mature, there are always challenges to overcome—often ones that don’t show up until changes are made for other reasons. In some of these cases, robotics can help conventional machinery when it gets into trouble. For example, Dick Motley, Fanuc Robotics senior account manager, describes an application for a beverage company that initiated a sustainability program in its secondary packaging, “light-weighting” all its bottles. The processor evolved its cartons from an overwrapped carton to a tray with a shrink configuration—then to a corrugated pad-shrink configuration and, finally, to just shrink wrap. While this new packaging worked well for carbonated beverages (carbonation’s internal pressure adds to the structural support of the bottle), water bottles just didn’t survive conventional bump-and-turn automation. They may as well have been water balloons. Motley says one of Fanuc’s integrators, Hartness, devised a robotic solution to prevent the destruction of water bottles in the bump-and-turn location. The idea was to have a robot gently grab and guide the product and shuffle it around the bend while it tracked the moving delivery conveyor. The robot was programmed to move at the same velocity as the conveyor and grab and guide bottles around the bump-and-turn location while a larger robot grabbed a layer at a time. Result: No more bursting water bottles. At the downstream end of robotics applications from packaging is palletizing. While palletizing is a mature technology, according to Rick Tallian, ABB segment manager for the US consumer industry market, it doesn’t mean processors are doing it right. “We find that people don’t question palletizing technology, and there are failure modes because [processors] are doing the wrong thing.” Palletizing is moving into a new world, and it probably doesn’t have to do with the mechanical equipment and the robot as much, but the software is pushing this stage into a new direction, he adds. According to Bill Torrens, RMT Robotics director of sales and marketing, in today’s distribution model, the pallet shouldn’t be used to store products before they’re shipped— unless a processor wants to load pallets, unload them to fill an order and restack a pallet to go out on the truck to a customer.

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T E C H U P DAT E

` Solutions that offer the flexibility to handle product types ranging from bags to natural products have been scarce in the food industry. Using vision algorithms, food processors can retrofit their solutions to handle products with highly variable dimensions. Source: Adept Technology.

98

Torrens calls his solution “palletizing avoidance,” and uses a staging area serviced by gantry robots for products that typically go out the door within eight hours, especially baked goods. With software connected to the manufacturing system, orders can be filled as “rainbow pallets,” mixed and matched to a customer’s preference. This concept doesn’t eliminate the use of pallets and warehouse space for seasonal goods, but it definitely alleviates the chaos of getting products out the door in a timely fashion. Process applications Because food products are not like machine parts, the former’s variability makes it tough to apply robotics to certain process applications. “I define processing as the handling of the raw or unpackaged food products,” says Staubli Robotics Food & Packaging Industry Specialist Bob Rochelle. “This market is not yet mature for industrial robotics and is defined as a growth area for Staubli. Because of this, we have invested in developing our HE model line specifically targeted to these applications. Currently there are minimal options for raw food handling or sanitary applications for traditional industrial robots. The issue is that traditional robotics has been tied to industries like automotive where sanitation is not a requirement. But this is beginning to change,” says Rochelle. One application is robotic meat trimming, but it hasn’t caught on as fast in the US as it has in Australia and Europe, says Craig Souser, JLS Automation president. There may be several reasons for this. The most important may be ROI, and it’s not good enough to make it a serious replacement for humans in most American meat establishments. Most non-US applications get government funding, and throughputs—while they may be ample in Australia and Europe—are not up to speed enough to compete with humans in US applications.

September 2011 | Food Engineering | www.foodengineeringmag.com

In Australia, Machinery Automation & Robotics (MAR), a robotics systems integrator, transformed a dangerous work environment at a meat processor with three safe, sanitary robotics solutions. The meat processor wanted a safer work environment for its employees, but also found it extremely difficult to hire and maintain reliable, skilled labor, particularly in the area of brisket cutting. “Traditionally, the brisket cutting part of meat processing requires a person to operate a heavy, industrial-size hydraulic knife device called a brisket shear,” says MAR CEO Clyde Campbell. “This practice combines a dangerous tool with a physically demanding task that commonly results in wrist and back injury. Our solution eliminated the need to endanger employees altogether.” MAR’s robotics installation features an ABB Model IRB 4600 industrial robot and an advanced sensing system to ensure accurate, reliable operation. A circular cutting saw, fitted with a dustless micro-toothed knife blade and centering guides, makes one clean cut at the center of the brisket. This has drastically improved quality with fewer instances of internal organ puncturing and other damage, simplifying downstream processing. Moreover, consistent submerging of the blade and guides into a cleaning solution after every cut sterilizes them more thoroughly and prevents cross-contamination. Touch and sight Touch (gripper technology) and sight (vision systems) are two key areas that are making it possible to use robotics in new applications. “The area of greatest focus for Adept Technology over the past few years has been in the handling of randomly oriented products that need to be placed into HFFS [horizontal form-fill-seal] or packaging machines,” says Rush LaSelle, director global sales & marketing.

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T E C H U P DAT E ` Machinery Automation & Robotics (MAR), an Australian robotics integrator, designed and built a brisket cutter, which makes one well-placed, sanitary cut. An ABB IRB 4600 robot uses an advanced sensing system to ensure accurate and reliable operation. Source: ABB Robotics.

“In the case of natural products typified by those in the proteins market (e.g., fish, poultry, beef and pork), vision systems and tooling alike have had difficulties in managing the variability associated with these products,” says LaSelle. Adept has responded by offering solutions that use vision algorithms to identify products with highly variable dimensions. These vision systems are also capable of conducting various levels of quality control and grading as the systems identify incoming products. Likewise, the company has worked extensively in compiling a suite of intellectual property surrounding the tooling needed to handle not only natural products, but through the use of advanced fluid mechanics, delicate products such as puff pastries at high rates of speed, without compromising the products’ integrity and appearance. Delicate food handling requires a special design for vacuum cup grippers, not devices you find at your local Ace Hardware store, says Tallian. Vacuum systems are a very critical link and usually need to be custom designed by integrators who understand the technology and food applications. With all the vision inputs and motion outputs to the robot, there has been a need not only for a robust robot controller, but also for some common system that can link the robot with connecting equipment—be it packaging systems, conveyors, etc. “One challenge that KUKA Robotics has met is the demand for a common control system on the packaging machine and on the robot associated with that machine,” says James Cooper, vice president sales and marketing. The robot supplier worked with Rockwell Automation to integrate a ControlLogix PLC control system. This allows the processor to use one common control system—one the processor’s operations staff already knows, adds Cooper. Ease of use With many vision systems being PC-based and easy to learn and set up via drag-and-drop “programming,” it’s no surprise processors are expecting the same of the entire robotics system—no matter where it’s working in the plant—processing, packaging or warehousing. “Easy-to-program software is what processors want,” says Tallian. “There is still too much engineering content in a robotic system.” Tallian says processors want to be able to make the simple product changes themselves without having to call in suppliers and integrators. Programming may get a boost from an unexpected source, says LaSelle. “The area where we might see the most advancement over the next five years will be the manner by which automation is deployed, configured and managed for product changeover. I expect there will be a heavy influence from gaming and consumer electronics to where programming of robots will be replaced with easier graphical interfaces and gesturebased programming.” 100

September 2011 | Food Engineering | www.foodengineeringmag.com

Performance evaluation Whether you measure the performance of a computer by GHz or MIPs, a car by horsepower or displacement or a robot simply by cycles per minute, you may not be getting an accurate representation of performance without checking it in an actual application. There are several factors that should be included in the performance evaluation, says Tallian. Raw performance is only one factor. Others include robot motion—how it’s developed and what tools are used with it. Other questions of concern: How suitable is the product for high-speed handling? What vision system is employed, and how can the product or part be located when placed randomly on a conveyor belt? “Just increasing the performance by 25 percent doesn’t mean you necessarily get a 25 percent increase in throughput in a production line,” adds Tallian. Czuday cites some typical performance expectations. For single pick-and-place applications with delta robots, performance is up to140 picks/min. If more than one product is handled, or if the gripping tool and product are heavier in weight, lower speeds can be expected, like 80 picks/min. Secondary packing applications reach up to 40 cycles per minute. Often layers or complete groupings of two to four packs are handled per cycle. This means big grippers and performance levels of up to 20 cycles/min. “In my opinion, often the physical properties of the product limit the performance, so I do not expect a strong increase of the performance level [of equipment in the immediate future],” adds Czuday. “Moreover, very fast pick-and-place cycles are perceived by many [processors] as being not as reliable as slower movements. Of course, people will get used to faster operations, but there seems to be some sort of ‘natural threshold,’ above which customers start to get worried about the robustness and reliability.” “Robotic systems are now capable of providing speeds that in many cases outpace the ability for today’s tooling to acquire and deposit products without damaging them,” says LaSelle. As

T E C H U P DAT E such, it would appear that increasing the speeds will be met with diminishing returns for production of items that are susceptible to damage, says LaSelle. “That said, many products and applications still have opportunities for higher rates, so as technology advances, it should be expected that speeds, performance and overall capabilities of robotic automation with improve.” Benefits and challenges With all the benefits robots bring to an application, there will be some concerns. According to Steven Hawkins, Stellar Automation Services director of automation, although robots decrease the number of operators, most processors will need to increase their maintenance staffs with people fluent in robotics. While there are fewer operators on staff to contaminate food products, robotic systems are complicated with a greater use of pneumatics and electronics, which demands a higher skill set from the maintenance staff. Hershey Foods needed an automated solution for packaging its Reese’s Peanut Butter Cup wrapped chocolates from six separate wrapping machines into 10-count (2x5) trays. The automated systems needed to handle a continuous flow of wrapped chocolates and paper trays and produce loaded trays for downstream wrapping. Saber Engineering designed and built three robot packaging systems using 3-axis AdeptModules and a multi-pick gripper that can pick 20 chocolates at once. The robots normally picked product from two incoming lanes simultaneously.

102

September 2011 | Food Engineering | www.foodengineeringmag.com

When a wrapper went down, the robot could dynamically switch to picking product from only one incoming lane. Saber installed a vision inspection system for each wrapper to inspect package quality before it entered the robot packaging systems. An Intellution SCADA system was installed to provide a single operator interface for all three packaging systems as well as providing data for production reports and IT. Food safety requirements When this kind of data from SCADA systems is available, track and trace gets much easier. According to Hawkins, while robots handle food, they’re also checking barcodes for traceability, tracking batch and lot numbers and checking for two or three different products coming down the same line—all this while not contaminating food with human illnesses. With a vision system, robots easily handle different sizes and types of products. In the pharma industry, tracing individual serial numbers is becoming more frequent, and this technology can be applied to the food industry if required. “Traceability has become a critical mandate for many who occupy a place in the food and beverage supply chain,” says LaSelle. “We are increasingly being asked to have the images of products fed to a database where they are recorded and tagged with the packaging and ultimately the lot with which they leave the facility. So, where robots are implemented with vision sys-

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T E C H U P DAT E ` Suited for high-volume production in bag and box palletizing operations, the Fanuc M-410iB/140H features a 140kg payload and slim arm and wrist design. A compact size allows it to work in small spaces with limited ceiling heights. Source: Fanuc Robotics.

batch numbers out of the supply chain based on the processor’s SCADA data. There isn’t a possibility for human error. “One of the big issues we discussed with pharma companies is they would have to track serialization into cartons and up the line,” says Tallian. “It wouldn’t surprise me if it’s going to fall into food, as well. That’s the virtual elimination of human intervention because humans can make [a wrong] decision where a robot is better because it does what it’s told to do.” Plan ahead If you’re new to robotic applications, there are three basic issues to keep in mind. According to Rochelle, one of the most common mistakes is that processors select a complicated application first. “I would recommend that the first-time robot user select a simple pick-and-place application to learn the process of integration, the trials of maintaining the system in running condition and as a base line to advance to more complicated applications,” says Rochelle. Souser makes a second point. Processors that approach systems integrators saying the main goal of their first robotics

tems, opportunities exist to utilize the images used for product location to also provide product traceability.” Tallian has put in systems that do a form of lot tracking. They process date codes with a specific barcode number and automatically record the time of this processing, so if the processor has a recall, it’s possible to pull all affected food down to lot and

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T E C H U P DAT E project is to replace two dozen people in the packaging area should not look at this as a short-term goal. Instead, make it a five-year plan, which at least allows processors to get accustomed to robotic applications—how workflows are affected and how maintenance is conducted. Closely allied to replacing people is the question of ROI for a robot installation. Czuday says that in general his customers aim at ROI of one to two years. However, the applications and product margins are very different. Often the performance and the flexibility (reduced setup time) are key arguments. But there are more processors that focus on investment costs, rather than operational and lifecycle costs. “We still battle ROI every day,” says Tallian. It’s still the major criterion for companies making decisions on whether to use a robot. Tallian feels processors are making more conscious decisions to help their employees by removing them from atrisk situations. “But we still have to get a lot closer to the hard numbers of being able to pay back [in replacing people’s jobs with robots].” Third, processors that plan robotic applications often reap benefits they never considered in the design phases of a project. Motley points to a processor in the baking industry. In the baking of specialty breads, the processor decided to place a robot at both ends of the band oven because of the ergonomic issues involved—reaching low to unload stacks of dough to

place in the oven and to remove the loaves after baking—all in a rather hot environment. When the process was automated, the robots were able to keep up and load and unload every available slot going into the oven, where their human predecessors left several empty slots. Because the oven was no longer “baking air” in the empty slots, throughput went up 80 percent. But an even bigger win was in energy savings per loaf of bread, which yielded nearly a 50 percent improvement. An improvement in throughput reduced the time needed to run the oven. “So while setting out to solve an ergonomic problem, the processor had no idea it would save this amount of energy,” says Motley. ❖ For more information: Brian Huse, Robotics Industry Association, 734-994-6088, [email protected] Rick Tallian, ABB Robotics, 248-391-9000, [email protected] Roland Czuday, Bosch Packaging Systems GmbH, 49 (7151) 7007-0; [email protected] Dick Motley, Fanuc Robotics, 248-377-7522, [email protected] Bob Rochelle, Staubli Robotics, 864-433-1980, [email protected] Craig Souser, JLS Automation, 717-505-3800, [email protected] Rush LaSelle, Adept Technology Inc., 925-245-3400, [email protected] James Cooper, KUKA Robotics Corp., 586-465-8817 Steven Hawkins, Stellar Automation Services, 904-899-9398, [email protected] Bill Torrens, RMT Robotics, 905-643-9700, ext. 273, [email protected]

When It’s Your Can

On the Line…

Allpax provides peace of mind for you and your retort room. We handle every kind of static and agitating retort process mode (even Shaka®) and just about any container you can throw at us (even pouches). But that’s only the beginning. Our retort controls are the best in the business, helping you through all your food safety initiatives.

If it’s in the retort room, we can do it.

Go to www.AllpaxRetorts.com or call 1-888-893-9277 for more information.

See us at Pack Expo Las Vegas Sept. 26th - 28th, Booth C-1416

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FREE WEBINAR

Process Optimization Tips to Help Get Tanks, Totes and Vats Cleaner in Less Time

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Tank Cleaning: Fact or Fiction? WEDNESDAY, SEPTEMBER 21, 2011 2:00 - 3:00 EDT The benefits of automated tank cleaning are generally well understood – reduced manual labor and more consistent cleaning. However, there are many aspects of automated tank cleaning that are widely misunderstood and prevent people from automating or achieving optimal results. This webinar will take a look at common misconceptions about automated tank cleaning in food processing. You’ll learn about why most of the perceived obstacles to automation aren’t really obstacles at all and how to optimize cleaning efficiency while using less chemicals and water. WHAT YOU WILL LEARN Tank cleaning experts will address these topics and separate fact from fiction: UÊ
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Experts in Spray Technology

FIELD REPORTS

Pass the herbs, hold the metal flakes

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Growing herb and spice processor increases quality with automated metal detection system that doesn’t eat up space.

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ooks and chefs all over the world use dried herbs and spices without giving a thought to the possibility small pieces of metal might be hiding in the packaging. This confidence comes about because the producers take great care to protect their brands by ensuring the products are not contaminated. A typical example is the German company, Laux GmbH, where product quality is paramount. Laux specializes in producing herbs, spices, teas, oils, vinegars and salad dressings for retailers. Before Laux grew to its current size, it painstakingly produced all its products by hand. With this kind of control, it was easy to produce superior products free of any contamination. “Because we had always processed our products manually, we had no need for metal detection,” says Technical Operations Manager Christoph Mertes. “When we expanded our spice mixture product range, the rapid increase in sales made it necessary to automate the filling process, which made the use of metal detection equipment essential to maintain our reputation for pure products.” Because metal fragments may be present in the incoming raw materials or enter the product during

` The ECOLINE-D metal detection system from S+S Inspection Inc. provides Laux with the assurance its products not only live up to their high quality, but also are free of metal contaminants. Source: S+S Inspection Inc.

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the manufacturing process, Laux inspects every jar of herbs and spices at the end-of-line, immediately before shipping. Like many companies, Laux must make the best use of the available production space, while not compromising the reliability of the inspection process. Mertes began his search for an inspection system that could perform without error in a tight space. “I used an Internet search engine and was impressed by S+S Inspection,” says Mertes. “It was important that the metal detection equipment be compact to fit easily into our production space, easy to set up for our different product groups and simple to maintain and clean. Equally important was the ability to detect both magnetic and non-magnetic metal contaminants.” To satisfy both space and detection requirements, Laux installed the ECOLINE-D metal detection system from S+S Inspection to check all of its glass jars of herbs and spices for metal contaminants. What attracted Mertes to the ECOLINE-D was the GLS coil technology that allows an exceptionally small, metal-free zone around the machine while maintaining the sensitivity demanded by Laux’s quality assurance policy. The entire length of the S+S system is only 750mm (29.5 in.) making it very easy to fit into the existing conveyor system. Although reliability and sensitivity are key considerations, the open, easily cleaned design that meets the strictest food industry hygiene standards combined with electronic control that makes operation simple and foolproof were also important considerations. The modular design of the system simplified installation and maintenance. At Laux, a contaminated pack causes the conveyor to stop and a signal light to flash so the product can be removed manually. When automatic operation is required, the inspection system can be fitted with a range of automatic rejection devices. “The S+S metal detection system gives us the sensitivity and reliability we need, combined with simple operation, straightforward maintenance and easy cleaning,” says Mertes. ❖ For more information: Doug Pedersen; 716-297-1922; [email protected]

FIELD REPORTS

Making in-flight pasta entrées bellissimo!

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Pasta-maker uses a carefully tuned, continuous cooking/cooling process to produce perfect pasta every time.

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erfect Pasta is the largest supplier of in-flight pasta meals to the airline industry, representing 30 percent of the company’s total annual sales. “If you are eating a pasta entrée on an overseas flight or on a first-class flight in the US, then you are most likely eating one produced by us,” says Mario Demarco, president of Perfect Pasta. Another 30 percent of the company’s business is supplying fresh pasta and pasta dishes to high-end restaurants throughout the Midwestern states. Forty percent of its business is supplying bulk pasta products to the foodservice industry and private labeling. Perfect Pasta has mastered the art of combining traditional Italian pasta-making techniques with the latest highly automated, continuous cookingcooling process technology, enabling the company to produce fine-quality, authentic Italian fresh pasta—including the long pastas—on a mass scale. Perfect Pasta’s 45,000-sq.-ft. plant can produce up to 5,000 pounds of fully cooked and prepared pasta meals per hour.

` The continuous process for cooking and cooling pasta and the flexibility of running multiple products throughout the production day at different temperatures and at different retention times are unique features of Perfect Pasta’s system. Source: Lyco Manufacturing.

To produce pasta at this rate, the processor designed a continuous-flow pasta cooking and cooling process line, and searched for equipment that could handle the demand. The system chosen and installed by Perfect Pasta was developed by Lyco Manufacturing. The cooker-coolers use two completely enclosed duo-rotary drum cylinders: one for cooking and one for cooling directly following in sequence. The drums have internal augers—a perforated skin sheet is wrapped around the drums and fixed to the auger’s flights. These flights gently move the pasta through the cooker and cooler system. The pasta is carefully agitated, while submersed in water, as it advances through the cylinders. Damage to fragile pasta products is a fraction of one percent. Once through the cooker machine, having reached the programmed temperature/time (in a first-in/ first-out sequence), the pasta is gently deposited into a following cooling drum, and chilled to its programmed temperature/time factor. The pasta is then released onto a belt conveyor for downstream combining with sauce, vegetables and other ingredients. The entrées are sealed and move into a spiral freezer where they are individually quick frozen (IQF) at -45°F, boxed and put into cold storage at -10°F to be shipped to the airlines. Consistent process parameters for temperature, time and recipes automatically control the pasta cooking and cooling hour after hour, and completely outperform the batch method and the Italian cooker formerly used by Perfect Pasta. “We are processing 500,000 pounds of pasta output per month through the cooker-cooler, an average of 20,000 pounds per day,” says Demarco. “The consistency of the pasta is excellent, and there is no clumping together. It is like cooking fresh pasta in a pot at your home. That’s how good this system is. The pasta floats in the water, and we can cook it anywhere from three minutes to 24 minutes at 206°F to 207°F, depending on what item we are making. The time and temperature are precisely monitored, and everything is charted, so we can also see the continuous temperature over time.” ❖ For more information: Jeff Zittel; 920-623-4152; [email protected]

www.foodengineeringmag.com | Food Engineering | September 2011

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PACK EXPO PREVIEW Innovation on display Offering a customer-centric approach, Las Vegas show continues to grow.

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ACK EXPO Las Vegas 2011, scheduled for September 26 to 28 at the Las Vegas Convention Center, will feature more than 1,600 exhibitors and cover more than 600,000 square feet. The trade show, produced by PMMI, will include special exhibit pavilions including The Brand Zone, The Processing Zone, The Pharmaceutical Pavilion and The Reusable Packaging Pavilion. For the first time in PACK EXPO history, the show will feature a Leadership Lecture, which will be delivered by Gen. Colin Powell, former US Secretary of State, National Security Advisor and chairman of the Joint Chiefs of Staff. The lecture is entitled “Diplomacy: Persuasion, Trust & Values,” and will be held at the Las Vegas Convention Center on Tuesday, September 27. A reception begins at 3:30 p.m., followed by Gen. Powell’s presentation from 4:30–5:30 p.m. Tickets for the Leadership Lecture are on sale at Packexpo.com for $125 per person. Group discounts are available. PACK EXPO 2011 will include approximately 50 educational sessions on topics such as sustainability, food safety and the Food Safety Modernization Act, serialization and project management. Taking a customer-centric approach to the educational program this year, PACK EXPO has partnered with five leading industry organizations to develop programming that directly addresses the needs of attendees. Conference partners come from a variety of disciplines and viewpoints within both processing and packaging: The Alliance for Innovation & Operational Excellence (AIOE); Converting & Package Printing (CPP) EXPO; The Institute of Packaging Professionals (IoPP); The International Society of Beverage Technologists (ISBT); and The Reusable Packaging Association (RPA). In addition to the program and exhibit highlights mentioned above, PACK EXPO Las Vegas offers attendees the following benefits: • The opportunity to connect with more than 1,600 suppliers and 25,000 colleagues • Total systems solutions for precisely integrated production lines • Cutting-edge technologies that apply in all vertical markets

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• An enhanced conference program presented by key industry players • Market-specific lounges for networking and education on the show floor: The Candy Bar, The Baking/Snack Break and the Rx Lounge • The future of retailing and packaging as envisioned by Clemson University • Material ConneXion’s display of the newest packaging materials available • The Showcase of Packaging Innovations—300 award-winning packages, and • The sixth annual PACK EXPO Selects Competition. ❖

PACK EXPO AT A GLANCE ` Where: Las Vegas Convention Center, Las Vegas, NV ` When: Monday, September 26 through Wednesday, September 28 ` Exhibit Hours: 9:00 a.m. to 4:00 p.m. ` Conference Sessions: Monday, September 26 and Tuesday, September 27 – 9:00 a.m. to 4:15 p.m.; Wednesday, September 28 – 9:00 a.m. to 1:45 p.m. ` Contact: 703-243-8555 or www.packexpo.com

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

A&B Process Systems Corp.

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.

Allpax Products The Allpax Advantage Allpax Products manufactures a complete range of severe duty sterilization and material handling machinery for food, beverage and pharmaceutical companies. From fully automated retort rooms to individual retort room components, our comprehensive line of turn-key equipment has helped us become one of the world’s leading sterilization solution providers. Our Automated Batch Retort System automates all functions of the retort room with easy-to-use controls and software, removing the complexity that usually accompanies the retort process. We also back our solutions with expert project management and installation from start to finish, full factory acceptance tests and 24/7 support to reduce potential production downtime. Products and Solutions Retorts: Allpax offers solutions for every type of retorting system available in sizes ranging from lab to production scale. We can handle nearly all containers in the marketplace today including challenging designs like pouches and fragile containers. We provide retort and sterilization solutions for the following processes: • Water Immersion • Saturated Steam • Steam-Air • Spray • Water Cascade • Rotary • Gentle Motion • Shaka® Material Handling: Allpax provides solutions for nearly any material handling and automation needed between sealing and packaging, including basket loaders and unloaders, conveyers, shuttles and other equipment going into and out of the retort room. Our advanced software, sensor and tracking systems allow our customers to manage a large-scale retort room with only one or two operators while preventing accidental distribution of under-processed products to market.

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

Contact: Allpax Products 13510 Seymour Myers Blvd. Covington, LA 70433 985-893-9277 www.allpax.com

See us at PACK EXPO Las Vegas booth #S6905

See us at PACK EXPO Las Vegas booth #C-1416

www.foodengineeringmag.com | Food Engineering | September 2011

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Atlas Copco Compressors LLC

The Austin Company The Austin Company’s Food & Beverage Group is an in-house team specializing in planning, designing and implementing safe, efficient and economical food and beverage facilities. From new construction to renovations and expansions, we offer a dedicated team focused exclusively on the food and beverage industry. Our services include:

Meet The Compressed Air Specialists! Atlas Copco has a focus on exceeding customer needs with a culture built on ongoing interaction, longterm relationships, and a commitment to understanding each customer’s process and objectives. As a result, every compressed air solution we create helps customers operate with greater efficiency, economy, and productivity. Satisfying customer needs with ground-breaking integrated compressed air technology, quality air accessories and 24/7 service support enhanced with remote monitoring tools positions Atlas Copco as a leading global compressor manufacturer. Our unwavering commitment is to be First in Mind – First in Choice® for all your compressed air requirements.

• Planning • Economic Analysis • Site Location • Architecture/Engineering • Process Engineering • Packaging Systems Services • Design-Build • Construction Management • Installation & Start-Up Our extensive experience includes successfully completed projects for all types of operations — baking and snack foods; beverages; condiments; confectionery; diary; frozen foods; grains; fish; produce; and specialty items. We have successfully implemented projects throughout the world including: • Manufacturing and Production Facilities • Bottling Plants • Formulation and Packaging Plants • Research Laboratories • Bulk Storage Warehouses • Automated Distribution Centers A KAJIMA USA Company

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Contact: Contact Name: Dorothy Samuel Phone: 803-817-7451 Address: 1800 Overview Dr. Rock Hill Sc, 29730 Web: www.atlascopco.us Booth #: s6021 E-mail: [email protected]

Contact: The Austin Company Food & Beverage Group Bob Graham, Vice President Food and Beverage 404-564-3964 [email protected] www.theaustin.com

See us at PACK EXPO Las Vegas booth #6021

See us at PACK EXPO Las Vegas booth #6602

September 2011 | Food Engineering | www.foodengineeringmag.com

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Baldor

Beckhoff Automation

Baldor Electric Company, headquartered in Fort Smith, Arkansas, designs, manufactures, and markets the broadest line of industrial energyefficient electric motors, power transmission products, adjustable speed drives, linear motors, motion control products, gear products, industrial grinders and generators. Baldor is the largest motor and mechanical power transmission company in North America and the second largest worldwide. Baldor•Reliance® motor products now range from 1/50 horsepower through 15,000 horsepower. Dodge® power transmission products include a wide variety of engineered mounted bearings and enclosed gear products. The addition of Maska® pulleys and couplings provides even more solutions as part of the Baldor product line. Baldor products are primarily manufactured in plants throughout North America; however, the company owns and operates plants in England, China and Canada as well. Products are available 24 hours a day, every day of the year, from sales offices and warehouses throughout North America, Europe, Latin America, Asia, the Pacific Rim and Australia. Products are sold in more than 70 countries to distributors and original equipment manufacturers in more than 160 industries. Baldor products, marketed for more than 100 years, have exceptionally strong brand recognition for quality and value with our customers. Baldor continues to lead the industry in delivering timely and complete product information to customers through our customer-preferred web site, as well as numerous printed catalogs. We also offer many training classes for distributors and end-customers to help them learn our products, technologies being used, application solutions and Baldor’s competitive advantages. Over 15,000 students have benefited from this training in the past 10 years. Baldor has an on-going commitment to employee education. Baldor employs approximately 8,000 employees worldwide and believes that well-trained employees make a better product. We also believe that better products translate into better value for our customers and shareholders. We have been elected by Training Magazine as one of the top 100 training companies in America. Many years ago, Baldor carefully defined “Value” in terms meaningful to our customers. Value is defined in terms of Quality and Service (both as perceived by the customer) in relation to Cost and Time. The result is our “Value Formula” which has become a part of our culture. It guides our thinking and directs our work every day.

Contact: For more information about Baldor, visit our web site at www.baldor.com See us at PACK EXPO Las Vegas booth #5940

Beckhoff Automation Introduces New Food-Grade Servomotors Dynamic AM3000 servo motors in new wash-down variant 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: Beckhoff Automation LLC Phone: 952-890-0000 Fax: 952-890-2888 e-mail: [email protected] www.beckhoffautomation.com See us at PACK EXPO Las Vegas booth #5228

www.foodengineeringmag.com | Food Engineering | September 2011

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Bel-Ray Company

Bimba For more than 60 years, Bel-Ray Total Performance Lubricants have proven their value, setting the highest standards of quality and performance as the worldwide leader in lubrication technology. Bel-Ray engineers products to perform and protect, while delivering superior business value for applications across a wide range of food engineering industries.

The first products Bel-Ray manufactured were for the food engineering industries and that commitment has not waivered. Industrial partners see increased equipment productivity and lower operating costs as a result of implementing Bel-Ray’s complete line of No-Tox Food Safe products. Kosher and Pareve approved, as well as Halal certified, Bel-Ray products meet all operational needs. Bel-Ray’s technical support representatives provide a Comprehensive Oil Analysis program that eliminates the one size fits all method of industrial lubrication. Working with each piece of equipment individually, the lubricant needs and frequency of maintenance can be determined allowing the equipment to operate at maximum efficiency eliminating downtime and increasing productivity. Using Bel-Ray’s full line of food safe products in your operation will reduce your energy consumption and give equipment a longer life-expectancy. In addition to the food engineering industries, Bel-Ray produces and delivers products worldwide for applications in aerospace, automotive, energy, marine, military, mining, motorcycle, OEM, powersports, steel, textile and other to industries served by the Powersports, Industrial and Mining Divisions. Market leading innovation continues. In early 2012, Bel-Ray will be introducing new formulas, new products and new packaging, all designed to increase the performance and function of Bel-Ray’s industry-leading products. Consolidated package sizes and types, easy to read labels and naming convention and a comprehensive cross reference and application chart are just some of the innovations included.

Contact: Bel-Ray Company PO Box 526 Farmingdale NJ 07727 Phone:732-938-2421 Fax: 732-938-4232 www.belray.com Email: [email protected] See us at PACK EXPO Las Vegas booth #6242

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Food processing environments put a diverse number of demands on your designs. That’s why whether it’s a simple clamping application, or a complex controlled closed loop bottle filling solution, Bimba is dedicated to delivering products that meet USDA requirements, improve efficiency, and reduce costs. And as always, when you work with Bimba, customer commitment comes standard. If you’ve got an engineering challenge, Bimba has the solution. Whether it’s a standard off-the-shelf cylinder or a cutting-edge custom assembly, Bimba is uniquely positioned to help you take control of any motion control application. In addition to its broad line of standard catalog products, Bimba also develops many custom and semi-custom products designed for specific customers and applications. The Original Line Electric Actuator This revolutionary design is built and tested to provide the greatest durability, highest speed and most thrust per dollar. These cylinder’s superior execution in applications requiring increased control and flexibility make the OLE ideal for various food processing applications. Roundline Repairable Stainless Steel Cylinder The round, smooth—bodied design prevents potential sources of bacteria growth and contamination and has proven ideal for washdown environments. Designed specifically for food processing applications, this is the only cylinder that meets USDA regulations. Valves From solenoid air valves to button valves, Mead Fluid Dynamics has the technology to handle the most demanding pneumatic control applications. An innovative approach to design allows these corrosionresistant valves to perform even in tough wash-down environments, while still yielding smooth speed and control.

Contact: Telephone: 708-534-8544 or 800-44-BIMBA Fax: 708-235-2014 [email protected] www.bimba.com See us at PACK EXPO Las Vegas booth #5435

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Bunting Magnetics Co.

Burns & McDonnell

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.

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.

®

“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 PACK EXPO Las Vegas booth #5327

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 IDFA booth #518

www.foodengineeringmag.com | Food Engineering | September 2011

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Chemetall

Convenience Foods

To ensure the reduction and elimination of contaminates, rely on Chemetall. We have provided superior sanitation solutions to the food industry for almost one hundred years. Our experience and expertise have resulted in the creation of over 300 products to meet the industry’s specific needs, including: • Caustic Cleaners • Chlorinated Cleaners • Floor Cleaners • Hand Cleaners • Sanitizers • Acid Cleaners • Defoamants • Non-Caustic Cleaners • Conveyor Chain Lubricants • Foam Cleaners • Rinse Additives • CIP Cleaners • General Cleaners • Water Treatment By working closely with our customers, Chemetall is also able to provide equipment tailored to specific processes such as: • Chemical Control Systems • Data Acquisition • pH Monitoring • Central High Pressure • CIP Control • COP Washing • Chemical Proportioning • Conveyor Lubrication • Conveyor Cleaning • Bulk Tank Storage • Foam Cleaning • Floor and Door Sanitizing Food industry customers enjoy the many benefits of Chemetall’s customized sanitation programs which include time, energy and manpower savings. Allow us to complete a complimentary evaluation of your current process so that we can create a complete customized sanitation solution that incorporates formulations, equipment, employee training, and technical support. With Chemetall, the only ingredient added is clean.

Contact: Michael Brancato, Director, Food/Non Metal Chemetall 675 Central Avenue New Providence, New Jersey 07974 Toll-Free: 800-526-4473, ext. 2444 Phone: 908-464-6900, ext. 2444 Cell: 609-865-0337 Fax: 908-464-7914 E:mail: [email protected] www.chemetallamericas.com See us at PACK EXPO Las Vegas booth #6529

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Come see the latest innovations in Packaging. From vertical FFS to thermoformers, GEA Convenience-Food Technologies offers top performance for most any application. CFS SmartPacker Due to its flexibility of application and sophisticated design the CFS SmartPacker out performs its competition. Reliable and user friendly, the machine is easy to operate and clean, while its advanced technical design keeps maintenance costs to minimum. The CFS vertical packaging machine offers a convenient and inexpensive means of packaging a wide variety of convenience goods – mainly protein – fresh shredded cheese, frozen vegetables, and confectionery snacks. With a range of materials and our variation in formats, ranging from standard flat pillow bags to more complex quatro seal or zipper bags, you are sure to find a packaging solution that fits your needs. Come see this machine along with other innovative applications at Pack Expo booth 6325.

Contact: 8000 N. Dallas Pkwy. Frisco, TX 75034 Toll Free: 1 800 388 9487 www.conveniencefoodtechnologies.com See us at PACK EXPO Las Vegas booth #6325

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

DCI, Inc. DCI, Inc., an employee owned company, has been a leader in the design, manufacturing and servicing of stainless steel/ other alloy equipment since 1955. The sizes and shapes of DCI manufactured equipment are as varied as the customers we serve. From 5 gallon process vessels to 500,000 gallon field-fabricated tanks, DCI tanks process, blend, store, heat, cool, mix and ferment the most trusted products and brands in the market. As a custom fabricator, we proudly serve the food, dairy and beverage industries with: • Tanks/Vessels (silo tanks, processors, starter tanks, whey crystallizers, round horizontal tanks, mix/blend tanks, • Dynamixer & Dynamixer Processor tanks, and DCI Site-Fab field-fabricated tanks). • Mixers/Agitators • Manways, Heads, Components • Replacement Parts • Field Service/Repair The DCI Dynamixer is designed to mix dry solids, semi-solids or liquids into a slurry or liquid product. This high speed mixer/blender may also be used to blend, disperse, reconstitute, dissolve, re-hydrate, prebreak or rerun soluble solids, soluble pastes and liquids quickly, efficiently and completely. Insoluble products are dispersed into liquids to make suspensions and slurries with greater stability and homogeneity. Models are available in a variety of shapes, sizes and motor horsepower to fit a broad range of applications. DCI’s Dynamixer Processor combines all the features of Dynamixer high speed mixer with the benefits of a cone bottom processing tank. It can perform three separate process functions all in the same tank. Mixing dry or semi-solids into a liquid, chopping and chipping solids, and heating and/or cooling the mixed batch.

Dorner Entire Food Industry Now Covered by Dorner’s Sanitary Conveyor Line From processing to final packaging, Dorner offers conveyor solutions for all major food markets. Food is essential to life – it provides the energy that’s so critical to keep people moving and performing at their best. And today, Dorner Mfg. Corp. is helping the entire food industry perform at its best with two innovative series of stainless steel, sanitary conveyors – AquaGard® and AquaPruf®. Dorner has unequaled expertise in the unique challenges presented by food handling and the company’s food conveyors can now tackle virtually any foodrelated application, from packaged snacks through raw proteins and dairy. The entire stainless steel conveyor line from Dorner is specially designed for fast and effective cleaning – from occasional wipe down to frequent high-pressure wash down. Plus, because they are all pre-engineered conveyors, the Dorner sanitary line can be shipped quickly to meet the immediate and frequently changing needs of the food industry. The majority of Dorner products ship within 10 working days or less, which helps customers achieve a fast ROI. Dorner’s Aqua family of conveyors are designed to meet the specific needs are in of the bakery, confectionery, fruit and vegetable, meat, seafood, poultry and dairy markets. All materials utilized for Dorner’s sanitary conveyors are FDA approved. In addition, hygienic designs are available from BISSC standards to USDA red meat and poultry accepted equipment. For additional details about any of the market leading sanitary conveyors from Dorner Mfg. Corp., please call the company at 1-800-397-8664 or simply visit www.dornerconveyors.com.

Contact: DCI, Inc. – Corporate Headquarters 600 North 54 Avenue (56303) P.O. Box 1227 (56302-1227) St. Cloud, MN – USA Phone: (320) 252-8200 Fax: (320) 252-0866 [email protected] www.dciinc.com

Contact: John Kuhnz, Director of Marketing Dorner Mfg. Corp. 975 Cottonwood Ave. Hartland, WI 53029 Phone: 800-397-8664 [email protected] www.dornerconveyors.com

See us at PACK EXPO Las Vegas booth #108

See us at PACK EXPO Las Vegas booth #3308

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Dur-A-Flex, Inc.

Emerson Process Management Stop paying for floors that don’t perform!

Model FMT Compact Integral High-Speed Filling Transmitter The Micro Motion Coriolis transmitter model FMT is specifically designed for high-speed, precision-fill measurement in filling and dosing applications. In a compact and lightweight design, the Filling Mass Transmitter is capable of measuring challenging fluids that contain entrained gas, suspended solids, or fluids with high viscosities.

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.

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Micro Motion offers the widest range of Coriolis meters dedicated to filling and dosing markets. Demand for flexible machines with rapid changeover, less product waste, and higher throughput rates make traditional filling technologies, such as piston fillers and magmeters, ideal candidates for replacement by Coriolis Filling Mass technology. Increase filling accuracy and throughput with the most versatile filling solution available today

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

• Coriolis mass-based measurement is immune to variations in process fluid, temperature, or pressure. Handles entrained gas, suspended solids, gases, aerosols, viscous fluids, aggressive fluids, and non-conductive fluids with equal ease. • Compatible with wide variety of integrated-valve-control strategies or traditional direct-pulse (external-valve-control) applications • Rapid line changeover with easy-to-clean, hygienic design that enables Clean In Place (CIP) • Integral design enables optimal space usage • Highest accuracy and fast response time enable tighter process control and reduce product waste

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: Emerson Process Management www.emersonprocess.com www.micromotion.com

See us at Pack Expo Show Booth #6820, Upper South Hall

See us at Pack Expo in Las Vegas Booth # C-4225

September 2011 | Food Engineering | www.foodengineeringmag.com

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Eriez

Mobil Industrial Lubricants

Metal Detector Conveyor Quick Ship Program Eriez’ Detector Conveyor Quick Ship program is design to match stocked conveyors and E-Z Tec® metal detector apertures to meet a one to two week delivery. Eriez’ stocks three stainless steel, wash down conveyor widths and five metal detector aperture heights per belt width for quick assembly and delivery. The variable speed conveyors are available in 12, 18 and 24-inch widths with a food-grade polypropylene belt.

Mobil Industrial Lubricants: Helping Food & Beverage Processors Ensure Food Safety, Optimize Equipment Performance and Minimize Downtime mobilindustrial.com Backed by more than 100 years of industry expertise, the team behind Mobil Industrial Lubricants continues to set new benchmarks in lubrication excellence to help its customers: • Improve food safety initiatives • Optimize lubricant consumption • Reduce downtime • Minimize maintenance costs • Boost productivity

• 12 x 60-inch belt with 6, 8, 10, 12 or 14-inch high apertures • 18 x 72-inch belt with 8, 10, 12, 14, 16, 18 or 20-inch high apertures • 24 x 84-inch belt with 12, 14, 16, 18 or 20-inch high apertures E-Z Tec metal detectors offer the highest level of protection against metal contamination. These units are competitively priced, designed and manufactured in the United States. These systems are ideal for customers in the food, textile, pharmaceutical, plastics, rubber, chemical and many other industries. Energy Efficient Feeders Eriez’ patented AC operated electromagnetic drive systems reduce power consumption by up to 60%! The watch-like precision of the variable speed AC drive has no moving or rotating parts and installs easily. Eriez offers high speed, high deflection and vertical feeders with a wide range of capacities.

Technology Leadership The team behind Mobil Industrial Lubricants manufactures technologically driven products utilizing a process that incorporates FDA component compliance, registering formulations with the NSF, strict production specification control, component receipt checks and specific manufacturing process controls. Mobil Industrial Lubricants H1 product portfolio and services include: • Mobil SHC Cibus Series: Synthetic lubricants ideal for hydraulic, gear, air compressor and heat transfer applications. • Mobil SHC Polyrex Series: Synthetic greases that offer extreme temperature performance. • Mobil DTE FM Series: Lubricants ideal for a wide range of applications, including use in bearings and hydraulics. • Mobilgrease FM Series: Greases that provide long-term corrosion protection. • SIGNUM Oil Analysis: State-of-the-art, online oil analysis program. These Mobil-branded H1 products comply with Title 21 CFR 178.3570 of the FDA for lubricants with incidental food contact and are manufactured in facilities that meet the industrial hygiene requirements of ISO 21469:2006. To learn more, visit Booth 7030 or mobilindustrial.com

Contact: 1- 888-300-ERIEZ [email protected] www.eriez.com See us at PACK EXPO Las Vegas booth #1208

See us at PACK EXPO Las Vegas booth #7030

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Fortress Technology Inc.

Fristam Pump

Fortress Technology Inc. is pleased to participate as an Exhibitor in the 2011 Pack Expo Trade Show. This year will be quite exciting for Fortress, as they will be launching the newest addition to their Phantom series, the STEALTH Metal Detector.

The evolutionary design offers full backwards compatibility ensuring spare parts and upgrades for additional functionality are readily available. This new STEALTH unit provides high-speed precision detection, while ultra-sensitivity levels detect the smallest metal contaminants.

In addition, Fortress will be displaying the “all-in-one” Vector Conveyor; Gravity, and Pipeline units. The metal detection solutions that will be on exhibit satisfy a variety of industries including: Bakery, Dairy, Meat & Poultry, Confectionery and Snack applications. Fortress PHANTOM metal detectors can also be customized to suit a company’s unique production line. Contact: Fortress Technology Inc. 1-888-220-8737 / 416-754-2898 [email protected] www.fortresstechnology.com

See us at PACK EXPO Las Vegas booth #S-5033

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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 PACK EXPO Las Vegas booth #6402

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

GEA Westfalia Separator Founded in Germany over a century ago, GEA Westfalia Separator offers a full range of products in the dynamic filtration and separation categories, including high performance separators, clarifiers, decanters and membrane filtration systems. We specialize in applying our technologies to the dairy, beverage and edible oil industries. Our equipment can be found in small and large food processing facilities. For small installations we offer Westfalia Separator ecoplus, a concept based on modular machines that can be upgraded as processing volumes increase. At the other end of the spectrum is the MSE 600, the largest dairy separator in the world.

Haskell Haskell is an acknowledged industry leader in the design and construction of world class manufacturing facilities for the food and beverage industry. As the nation’s leader in sustainable design and construction, Haskell builds energy efficient facilities for Top 50 companies in the industry and has long been known for its innovation in design and efficiency in project execution. The four walls and everything within Global Reach Haskell supports our multi-national customers with engineering and construction services across the globe. From our headquarters in Jacksonville, corporate offices in Atlanta, Dallas, and Mexico City, and project offices worldwide, Haskell serves our customers in North America, Latin America, Europe and Asia. Expanded Portfolio Haskell has expanded its product offerings to include both process and packaging system integration. Through organic growth and acquisition, Haskell now has a full complement of system integration engineers with years of experience in virtually every segment in the food and beverage industry.

We also offer Westfalia Separator capitalcare, a program developed to protect our customers’ investments. This all encompassing program includes original spare parts, around-the-clock service and factory authorized repair facilities. Our goal is to ensure safe operation and maximum performance over the life of the equipment. Westfalia Separator wewatch, is another special program. This remote data collection and transmittal system continuously records centrifuge vibration and process data and interprets its meaning. It allows our customers to eliminate unscheduled downtime by predicting and preventing equipment failures and diagnosing the root cause of a problem.

Contact: GEA Westfalia Separator 100 Fairway Ct. Northvale, NJ 07647 Phone: 201-767-3900 E-mail: [email protected] www.wsus.com See us at IDFA booth #1239

Experienced Resources Our team of over 700 engineers and construction managers are experts in project delivery for the food and beverage industry, consumer products industry and other manufacturing industries. This diverse expertise adds value to our customers as we bring technologies and approaches from a wide range of applications to the table as we search for innovative solutions to meet their business needs. Flexible Contracting At Haskell we focus on the business needs of our customers and are flexible in our approach to contracting. We are prepared to deliver complete solutions for facilities and systems under an Engineer, Procure, and Construct (EPC) contracting arrangement but will also support the customer with subsets of that approach as needed. Certainty of Outcome Our promise to our customers is certainty of outcome. Through our EPC delivery methods we are prepared to take on every aspect of project delivery and provide an end-to-end solution. We have the integrated team of professionals required to make that commitment to you and are prepared to back up that claim by taking on the risk that must be managed to achieve a successful outcome. With Haskell you can be assured we will deliver “The four walls and everything within”. Contact: Haskell - Corporate Headquarters 111 Riverside Ave. Jacksonville, FL 32202 Phone: (904) 791-4500 FAX: (904) 791-4699 www.haskell.com See us at PACK EXPO Las Vegas booth #6427

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

JBT FoodTech

Key Technology 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.

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.

• 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.

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

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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 See us at PACK EXPO Las Vegas booth #4509

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Lubriplate Lubricants Company

Magnum Systems

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.

Magnum Systems provides a “Single Source” approach to the design and manufacturing of pneumatic material conveying and packaging systems solutions for powder and bulk solids. The total systems approach allows Magnum Systems, through its two operating divisions, Smoot and Taylor Products, to integrate the entire process from pneumatic conveying of material to the packaging machine to complete automation of container handling from railcar to pallet. Taylor Products, the packaging division of Magnum Systems, a leader in the design and manufacturing of packaging automation systems and equipment, offer a broad range of modular packaging equipment engineered to perform alone or as a totally integrated packaging process system. Offerings include open mouth bag filling, valve bag filling and intermediate bulk loading and unloading equipment. Smoot, the conveying division of Magnum Systems, has engineered and manufactured pneumatic equipment and systems for over 50 years. The selection of the correct style of transfer system is critical to having regular and reliable plant operations. With the extensive experiences and successes in pneumatic conveying systems, Smoot can assist in deciding which type will best fulfill the needs at the lowest cost to install, operate and maintain. Taylor Products and Smoot will analyze your process and test your material in their fully equipped test facilities. Then design and build a system functionally integrated into your operation to exceed your expectations.

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 PACK EXPO Las Vegas booth #S-6118

Contact: Gary Saunders Magnum Systems Vice President Sales and Marketing 1250 Seminary Street Kansas City, Kansas 66103 www.magnumsystems.com See us at PACK EXPO Las Vegas booth #3600

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

METTLER TOLEDO

Reiser

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 C541 and learn how our solutions can increase efficiency, reduce manufacturing costs and improve the competitiveness of your business and you could win $1,000 gift certificate for Travelocity! 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. 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.

Reiser supplies a complete line of equipment to help food processors produce all types of prepared food and deli salad products. Our range of equipment includes AMFEC mixers, Vemag portioners, Vemag cup fillers, and Vemag slice depositors for sandwich making. AMFEC Mixers AMFEC Mixers are ideal for gentle blending and mixing of even the most delicate products. A variety of agitator options are available, including their exclusive Faster Mix agitators (both paddles and ribbons), which eliminate the “logging” effect often seen in other Mixers. Vemag Portioners The Vemag Portioner is a food pump that provides the highest level of portioning accuracy, production efficiency and versatility, while consistently producing a high-quality product. The Vemag features a powerful, positive displacement double-screw pump that transports product extremely gently and without damage. A variety of innovative attachments make the Vemag a highly versatile machine. Vemag Cup Fillers The Vemag Portioner with a Dripless Valve filling head attachment can be used to fill all types of containers – cups, tubs, pails and trays – accurately and gently without mess or container contamination. This is an economical solution to easily fill containers with exact-weight portions. Vemag Slice Depositors The Vemag Portioner with a Slice Depositor attachment is the perfect solution for producing all types of sandwiches quickly and easily. It deposits exact-weight portions of product mixtures such as tuna salad, chicken salad or condiment spreads directly onto sandwich bread. It portions cleanly and evenly, with no mess.

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.

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 PACK EXPO Las Vegas booth #C-541

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Contact: 725 Dedham Street Canton, MA, 02021 Telephone: (781) 821-1290 Fax: (781) 821-1316 [email protected] www.reiser.com See us at PACK EXPO Las Vegas booth #5335

PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

SIEMENS

SlipNOT® Metal Safety Flooring

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.

SlipNOT® non-slip stainless steel products transform slippery food processing environments into high traction work areas. SlipNOT® safety flooring products are used by food and beverage facilities to increase productivity and Non-slip stainless steel plate keeps workers worker safety while reducing safe at a meat processing facility. injury and liability. SlipNOT® products are very versatile and can be used as floor plates, grating, ladder rungs, stair treads, ladder rungs, crossovers, drains covers and platforms among other uses.

• 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.

SlipNOT® products are 100% grit free. The file hard surface is between 55-63 on the Rockwell “C” scale and has a bond strength of at least 4,000 psi. SlipNOT® non-slip products exceed all standards set by ADA and OSHA and are registered by NSF International. SlipNOT® safety flooring products provide a long lasting maintenance free alternative to slippery diamond plate and fiberglass SlipNOT flooring is available in products, while withstanding the caustic a variety of products to fit any enzyme environments that are found in many environment. ® food processing plants. SlipNOT anti slip flooring cleans easily by standard methods such as power washing and brushing. ®

SlipNOT® slip resistant products are available in stock sizes or can custom fabricated to detailed specifications. They can be sheared, welded, flame cut, torch cut, laser or water-jet cut, plasma cut, countersunk, and drilled for complete versatility both in the shop and field. SlipNOT® stainless steel slip resistant products create instant long lasting safety in every direction.

Contact: Siemens Industry Inc 1201 Sumneytown Pike Spring House, PA 19477 (423) 747-5850 www.usa.siemens.com/foodbev [email protected] See us at PACK EXPO Las Vegas booth #3434

Contact: Slip resistant grating allows slippery substances to drain through while Sales keeping employees on their feet. SlipNOT® Metal Safety Flooring 2545 Beaufait St. Detroit, MI 48207 Ph. 313-923-0400, 800-SLIPNOT Fx. 313-923-4555 Website: www.slipnot.com Email: [email protected] Women Owned: WBENC Certified Company See us at PACK EXPO Las Vegas booth #C-4819

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PACK EXPO LAS VEGAS AND INT’L DAIRY SHOW Previews ADVERTISEMENT

Spraying Systems Co.

See New SprayDry® Nozzles plus Tank and Dryer Cleaning Equipment at the International Dairy Show, Booth 813 See our complete line of SprayDry nozzles including our new SV Series SprayDry® nozzles with swirlchamber design that provide comparable performance to competitive nozzles. SV nozzles last longer, cost less and are readily available with more than 700 swirlchamber and orifice combinations. Available with hundreds of core and cap combinations, SK and SB SprayDry nozzles are available with Maximum Free Passage (MFP), antibearding and hand-tight features to extend production runs and minimize maintenance. WhirlJet® SprayDry nozzles feature large orifices for producing large particles in high-volume operations and are available in a wide range of styles and sizes. Plus, you can watch TankJet® tank cleaners in action and see how to get dryers, vessels and tanks cleaner in less time. Products on display include the TankJet 360, a high-impact fluid driven machine for dryers up to 100’ (30 m) in diameter and the TankJet AA190, a motor driven unit for tanks up to 34’ (10.4 m) in diameter, for high-impact, dependable cleaning with virtually no maintenance. Several other tank cleaners will also be featured including 3A sanitary spray balls.

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

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www.foodengineeringmag.com | Food Engineering | September 2011

133

AD INDEX

April 22-25, 2012 Sanibel Harbour Marriott COMPANY

PHONE NUMBER

PAGE

•

COMPANY

Fort Myers, FL PHONE NUMBER

A&B Process Systems

888-254-2789

74

Industrial Magnetics, Inc.

888-582-0821

47

Admix Inc.

800-466-2369

52

JAX

800-782-8850

20

626-576-0144

42

JBT FoodTech

www.jbtfoodtech.com

5

Air Blast, Inc. Allpax Amerivap Systems Anderson Instrument Co Arizona Instrument LLC

106 40

Lubriplate Lubricants Co.

800-733-4755

11

800-833-0081

50

Marchant Schmidt Inc.

920-921-4760

14-17

800-528-7411

Austin Company

BD Biosciences

6

Key Technology

509-529-2161

800-652-2532

42

Masosine Process Pumps

800-282-8823

51

www.theaustin.com/foodgroup

39

Material Transfer & Storage

800-836-7068

26

888-828-4920

81

Mettler-Toledo Safeline

www.bdbiosciences.com

27

Mobil Industrial Lubricants

www.beckoff.com/stainless-steel-panel 67

Bel-Ray

www.-bel-ray.com

2

Bimba

800-44-BIMBA

12

Breddo Likwifier

800-669-4092

IBC

Martin Brothers

94

83

Baldor Electric Company

Beckoff

888-893-9277 404-350-0239

800-682-4594

Ashworth

Mueller

800-221-2624

33

www.mobilindustrial.com

BC

800-MUELLER

22

Nercon Engineering & Manufacturing Inc. 920-233-3268 Nord Drive Systems

800-628-8139

46

Perfex

Buhler Aeroglide

919-851-2000

49

Process Expo

101

www.nord.com

Omega Engineering Inc.

Brookfield Engineering

70-71

888-82-OMEGA

1

800-848-8483

24

www.myprocessexpo.com 60-61

Bunting Magnetics Co.

800-835-2526

104

Power Engineers

888-687-8811

Burns & McDonnell

816-822-3831

65

Reid Supply Company

800-253-0421

43

Chemetall

800-526-4473

55

Reiser

781-821-1290

86

Clarion White Oils

34-35

Relco

320-231-2210

6

320-252-8200

82

Rytec

888-GO-RYTEC

51

Demaco

321-952-6600

32

Ross, Charles & Son Company

800-243-ROSS

21, 23

Dorner

800-397-8664

37

Schenk Accurate

800-394-2941

56

Douglas Machine

800-331-6870

59

Siemens

800-253-3539

54

SlipNOT Metal Safety Flooring

97

Sonic Air Systems

Emerson Micro Motion

855-MY-CLARION

105

DCI Inc.

Dur-A-Flex

800-992-1776

Eriez Magnetics

888-300-ERIEZ

18, 92

Flexicon Coporation

888-353-9426

30

SPX

www.usa.siemens.com/foodbev 103

Spraying Systems Co.

800-SLIPNOT

38

800-82-SONIC 800-95-SPRAY

36 80, 93

www.spx.com

IFC

Flottweg Separation Technology

859-448-2300

46

Summit Industrial Products

800-749-5823

44

Fortress Technology

888-220-8737

102

Tel-Tru Manufacturing Co.

800-232-5335

59

Terlet USA

800-965-6065

10

Thermo Scientific

800-227-8891

73

Triple S Dynamics, Inc.

877-542-8010

9

77

Ultrachem Inc.

302-325-9880

47

219-464-4811

91

800-822-8629

69

Fristam Pumps

800-841-5001

7

Gamajet

877-GAMAJET

52

GEA Convenience-Food Technologies www.geaconveniencefoodtechnologies.com GEA Westfalia Separator, Inc.

800-722-6622

45

Urschel Laboratories, Inc.

Hapman

877-314-0733

99

Vac-U-Max

Harpak

800-813-6644

58

Wenger

816-891-9272

28

Haskell

904-791-4500

84

Wire Belt Company of America

603-644-2500

89

800-227-5980

41

Woodward & Curran

www.woodwardcurran.com/fe

79

877-292-5715

48

Zeppelin Systems

813-920-7434

50

Heat & Control Hinds-Bock Corporation Inpro/Seal

www.inpro-seal.com

4

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

134

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September 2011 | Food Engineering | www.foodengineeringmag.com

ENGINEERING R&D Kevin T. Higgins, Senior Editor

New solution for slaughter

`

Systems development can create strange bedfellows. Take, for example, the alliance between an Alabama road construction firm and food scientists addressing animal welfare issues. A number of notable individuals hail from tiny Kosciusko, MS, with Oprah Winfrey and blues harpist Charlie Musselwhite heading the list. Kosciusko’s latest claim to fame may be controlled atmosphere stunning (CAS) technology for poultry slaughter. Unlike other CAS systems, the system developed by Kosciusko-based TechnoCatch LLC relies on oxygen removal rather than lethal gas injection, resulting in a kill that addresses both animal welfare concerns and human discomfort in one of the food industry’s most difficult work environments. TechnoCatch is a business unit of JC Cheek Contractors Inc., a road-building family firm. Cheek became involved in food-related equipment development in the 1990s, when Hollis Cheek partnered with Cattaruzzi International, an Italian supplier of poultry processing equipment, to develop a mechanical chicken harvester. With the interest in animal welfare increasing, the TechnoCatch team began exploring alternatives to carbon dioxide for CAS. Developers reasoned removal of oxygen would produce the same results at a lower cost and without greenhouse gases. The concept had been applied on a limited basis world-

` Randolph Cheek, vice president, JC Cheek Contractors Inc., & principal, TechnoCatch, Kosciusko, MS. Source: TechnoCatch LLC.

wide but never in the United States, where the American Veterinary Medical Association (AVMA) long has considered decompression an unacceptable method of euthanasia. But that didn’t detour developers, who have worked closely with food scientists and veterinarians to develop their low atmospheric pressure system (LAPS). Over the course of several minutes, pressure in the chamber is lowered to about 5psi from the typical 14.7psi. Research on chickens’ stress levels was conducted in conjunction with prototype development, and the first commercial unit is up and running at Fort Smith, AR-based OK Foods Inc. A letter of no objection was issued by USDA’s office of New Technology Testing Approval in spring 2009, and the system is certified by the American Humane Association. Overseeing development of LAPS is H. Randolph Cheek, vice president of JC Cheek Contractors and a principal in TechnoCatch. He is a business school graduate of Mississippi State University (MSU) with a major in risk management and insurance. FE: When did development of low atmospheric gas expansion in animals’ gastrointestinal tracts. But pressure for stunning chickens begin? gases are not likely to be trapped in chickens’ abdoCheek: Preliminary discussions began nine to 10 mens, and the rate of oxygen removal is much slower

years ago, after our collaboration with Cattaruzzi resulted in an alternative to hand-catching of birds at the farm level. I was in my junior year in college in 2004 when my father asked me to meet with Drs. J. Paul Thaxton and Yvonne Vizzier-Thaxton at MSU’s poultry science building. A live chicken was placed in a pot with a plexiglass top and a hose to suck out the air. We watched to see if this approach would effectively stun the chicken without causing pain or distress, and it worked. The AVMA ruled decompression to be unacceptable based on rapid rates of oxygen removal that cause

in our system than in earlier versions. Cycle time in the chamber is four minutes, 40 seconds, which results in a slow, precise, irreversible stun. FE: Carbon dioxide mixtures are used successfully to stun hogs and other livestock. What advantage does oxygen removal offer? Cheek: The cost of CO2 alone is a problem. If it was

used extensively in animal slaughter, the price per ton would go through the roof. Additionally, birds can sense CO2 because the gas burns their nostrils and throats. Birds don’t have a low-oxygen sensor.

www.foodengineeringmag.com | Food Engineering | September 2011

135

ENGINEERING R&D (HACCP-based inspection model project), with two high-speed lines. The four chambers can deliver up to 400 chickens a minute. We knew if we could make the system work at a HIMP plant, it would work anywhere in the country. FE: What were some challenges in building the system? ` Four chambers in the dock area of OK Foods accept chicken transport cages for stunning with low atmospheric pressure. Extensive research on the animal welfare and food quality implications preceded the system’s commercial deployment. Source: TechnoCatch LLC.

Electrical stunning is judged by AVMA to be a humane slaughter method, though for the four to five minutes from the time live birds are dumped from a cage and then stunned and shackled, there is stress. One measure of this is the stress hormone corticosterone. Research shows that the level of corticosterone with LAPS is half that of electrical stunning. FE: Is there pain associated with oxygen starvation? Cheek: Initial tests using EEG and EKG

readings in December in the Netherlands suggested no pain, based on brain function. We need to be able to answer all questions about the impact on the neurology of the birds. Hypoxia is the cause of death with this methodology. Hypoxia can occur with loss of cabin pressure in an airplane, which is why pilots undergo training so they recognize the symptoms. A feeling of euphoria precedes unconsciousness in humans. It’s possible birds have a similar experience. FE: How large is the system’s footprint? Cheek: The OK Foods installation is

in the back dock area and includes four chambers, with transport cages feeding into each. The overall dimension is about 60 by 60 ft. It’s a HIMP plant 136

Cheek: We had never built a convey-

or before, and PLC programming for sequencing the cages was one of the bigger challenges. We started with a base program, but 10 times more code had to be written than was originally envisioned. While the cages all are square in a computer design, they aren’t necessarily true or square or don’t roll perfectly in reality. Placement of prox switches and sensors to identify and resolve issues in the sequencing of the cages was a long process. Tracing problems could only be done on the weekend, for the most part. FE: What changes occurred with the original system design? Cheek: A year ago, the chamber held

one transfer cage. To reach commercial scale, we had to accommodate two. After consulting with [animal welfare expert] Dr. Temple Grandin, cameras were installed inside the chambers so plant personnel could identify a disruption that is resulting in pain. At Dr. Grandin’s insistence, the operator has no control, other than the ability to turn the system on or off. That stemmed from her work with cattle and pigs and the incidence of human error. Cattle are rendered insensible with a shot from a captive-bolt gun, for example. In welfare audits last year, operators failed to deliver a lethal shot up to 5 percent of the time, resulting in unnecessary suffering. FE: Does LAPS impact product quality? Cheek: Blood flow during exsanguina-

tion differs from electrically stunned birds, though blood loss volume was similar during testing. Breast meat quality is excellent,

September 2011 | Food Engineering | www.foodengineeringmag.com

and decreased stress levels minimize problems such as pale, soft and exudative meat. Carcass quality is at least equal to electrical stunning. And unlike conventional slaughter, where fecal matter is released on the line, the birds evacuate their colons before entering the plant, which may have a positive impact on bacterial counts. Wing damage occurs more f requently than with electrical stunning, though controls optimization has reduced the variance. FE: Why are there higher levels of wing damage? Cheek: With the onset of loss of posture,

which is tied to unconsciousness and elimination of pain, the birds get on their backs, and wing-flapping usually occurs as they go into their death struggle. Because they fall on top of each other, wing damage can occur. Additionally, the birds’ wings are a lot more limber than with electrical stunning, requiring an adjustment to the mechanical picker. The damage is dislocations, not compound fractures. OK Foods sought strict limits on the level of wing damage. The rate varies depending on the weight of the birds. OK Foods uses electric stunning for 20 minutes before shift changes. That establishes a baseline for comparison with LAPS. They said we can’t be more than 2 percent above the limb damage rate with electrical each day. FE: How does LAPS impact workers? Cheek: For workers, it’s a complete 180°

in the operating environment. OK Foods used to have to bring in temporary workers in the hanging room every day. Now, turnover is just about gone. Typically, the hanging room is dark, workers need protective clothing, and there’s lots of dust. With LAPS, the lights are on, there’s no dust, and the experience is less traumatic for both the birds and the workers. FE: Do you see LAPS as mainstream or niche technology? Cheek: It will become mainstream

because of the interest in the welfare of the animals we eat. ❖

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