Food Engineering 2015 09

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T H E M A G A Z I N E F O R O P E R A T I O N S A N D M A N U F A C T U R I N G M A N A G E M E N T

September 2015 | www.foodengineeringmag.com

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September 2015 | www.foodengineeringmag.com

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3www.foodengineeringmag.com | Food Engineering | September 2015

www.foodengineeringmag.com

S e p t e m b e r 2 0 1 5

FEATURES COVER STORY

62 The World’s Top 100 Food & Beverage Companies Global volatility in both socioeconomic and political terms, shifting demographics and an explosion in e-commerce created an increasingly challenging backdrop to activities during the past year.

77 Weighing All the Options in Wastewater Treatment

Whether your plant is located in a drought-stricken area or where water is plentiful, building a wastewater treatment center on site may be cost effective for several reasons.

101 Solutions for Improving Yield You’ve done the obvious, so where else can you look to

squeeze out more product? There are gains still to be realized in managing the risky aspects of operations—from line startup to changeovers to new product introductions.

121 Tech Update: Filling Equipment As consumers want a bigger variety of healthier

choices that come in a plethora of sizes, manufacturers are offering fillers that are flexible while producing optimal output.

8 Editor’s Note

10 Calendar of Events

15 Manufacturing News Barriers to energy savings

21 Food Packaging Pushing away from petroleum

27 Food Safety Time to use some common-sense protocols

31 Technology Sourcebook Focus on Checkweighing & Metal Detection and

Spraying & Washing Equipment

128 Field Reports Precision weighing technology increases accuracy.

132 PACK EXPO Preview

155 Classified Ads

159 Engineering R&D Lubrication keeps wheels turning in flash freezing

applications.

21

27

31

128

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63DEPARTMENTS

4 September 2015 | Food Engineering | www.foodengineeringmag.com

FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT:

Tel. 847-763-9534 or Fax 847-763-9538 or e-mail [email protected]

EDITORIALJoyce Fassl Editor in Chief

[email protected], 610-436-4220 ext. 8519

Wayne Labs Senior Technical [email protected], 215-345-4548

Debra Schug Features [email protected], 847-405-4068

Jeremy Gerrard Digital/Online [email protected], 610-436-4220 ext. 8511

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Richard Stier, Jaan Koel, Mark Huffman

Contributing Editors

ART & PRODUCTIONKarla Fierimonte Art [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

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AUDIENCE DEVELOPMENTKourtney Genereaux Audience Marketing Project Manager

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FOOD ENGINEERING Volume 87, Issue 9 (ISSN: Print 1522-2292 and Digital 1937-4429) 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.: $123.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $160.00 USD (includes GST & postage); all other countries: $178.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2015, 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 represen-tations. 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 IMEX Global Solutions, 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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NORTH AMERICA SALESPatrick Young Publisher & District Sales Manager

610 Willowbrook LaneWest Chester, PA [email protected]

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

and LI, VA, MD, DE, Washington DC

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Tel: 847-405-4048; Fax: 248-502-1017Midwest and Northeast Territory: Northern IL, WI, MN, IA, KS, MO, SD, ND, CO, WY, NE, TX, OK, NM, AR, NH, VT, MA,

RI, ME, Saskatchewan

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[email protected]: 440-564-5732; Fax: 248-502-2088

Midwest and Southeast Territory: OH, IN, WV, KY, TN, MI, NY, Western PA, FL, GA, NC, SC, AL,

Southern IL, MS, LA, Ontario, Quebec

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San Francisco, CA [email protected]

Tel: 415-387-7784; Fax: 415-387-7855West Coast Territory: AZ, CA, OR, WA, AK, UT,

ID, HI, British Columbia

Carolyn Dress Inside and Online Sales ManagerTel: 847-405-4046; [email protected]

Suzanne Sarkesian Classified Sales ManagerTel: 248-786-1692; [email protected]

INTERNATIONAL SALESGabriele Fahlbusch

IMP InterMedia Partners GmbHTel: 49 (0)202-27169-15; Fax: 49 (0) 20227169 20

[email protected], Switzerland and Austria

Fabio Potesta Mediapoint & Communications SRL

Tel: 39-010-5704948; Fax: 39-010-5530088 [email protected]

Italy

CORPORATE DIRECTORSPublishing John R. Schrei

Corporate Strategy Rita M. FoumiaContent Deployment Michelle Hucal

Creative Michael T. PowellEvents Scott Wolters

Finance Lisa L. PaulusInformation Technology Scott Krywko

Human Resources Marlene J. WitthoftProduction Vincent M. Miconi

Clear Seas Research Beth A. Surowiec


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E D I T O R ’ S N O T E

Joyce Fassl, Editor in Chiefe-mail: [email protected]

Going far without going too far

or as long as I’ve been overseeing the content of Food Engineering magazine, the mandate for food and beverage processors has been serv-

ing consumer needs. In the past decade, how-ever, the pressure to deliver the right goods to consumers has become even more intense.

I am referring not only to formulation changes and product l ine ex pansions, but also to food safety and sustainability improvements and how food and beverage makers communicate with the public.

As the cover story of this issue states: Change is the new normal. As consumers request formulation changes such as elimi-nating dyes and incorporating more natural ingredients, I agree this is a step in the right direction. However, food and beverage man-ufacturers walk a fine line whenever changes are made to formulations. Sometimes when products contain more natural ingredients, sales take a dive. Consumers may say they want the real deal in products, but don’t always like the resulting taste.

Another massive change we’ve seen in the past decade is the rise of the digital age. Who would have predicted that Facebook, Twitter and specialized blogs and websites would wield so much power over our indus-try? In addition, digitally savvy consumers in some parts of the world are food shop-ping on cell phones. (See pages 72-74 in this issue.) I can’t see myself doing that any time soon, but I can understand how it might become the norm in the next 10 years. Here again, the industry must walk the fine line between giving consumers too many digital messages and providing just enough to sup-port their needs.

In the future, I hope the food and bever-age manufacturing industry will be suc-cessf ul in going far beyond consumer expectations, but not go so far that it turns off consumers. In any event, I’m sure the emerging generation of consumers will not be shy in letting our industry know—digi-tally, of course—exactly what they want or think they want. ❖

F

Bob ReedVice President Global Engineering

Kellogg Company

Ed DelateVice President,

Global Engineering and

Corporate Social Responsibility

Keystone Foods LLC

David WatsonVice President-Engineering

Campbell Soup Company

International and Baking

Technology

Sam CaseyDirector of Engineering

Keurig Green Mountain, Inc.

Greg FlickingerVice President, Manufacturing &

Corporate Engineering

Snyder’s-Lance Inc.

Diane WolfFormer Vice President,

Operations and Engineering

Kraft Foods

Daniel SileoPlant Manager

SugarCreek

Pete HockSenior Director,

Continuous

Improvement

ConAgra Foods

Food Engineering Editorial Advisory Board

Re•tro•fit: verb - to install (new parts) in something previously manufactured or constructed You talked. We listened. You wanted easier sanitation of the gates and you wanted the sanitation process to be quicker. You wanted to just retrofit this new gate into your existing Slipstick® Horizontal Motion Conveyors. The Triple/S Field Service Team had ideas about this new gate and set out to build one for our Test Lab. The new Eco-Gate is tool-less and opens from the side of the conveyor. One major food manufacturer retrofitted one Eco-Gate as a test and liked it so much they installed 15 more!

Visit www.sssdynamics.com or call us today at 1-800-527-2116 and see how our retrofit can save you time and money. It was your idea.

from the side of the conveyor. One major food manufacturer retrofitted one Eco-Gate as a test

or call us today and see how our retrofit can

Re•troverb - to install (new parts) in something previously

You talked. We listened. You wanted easier sanitation of the gates and you wanted the sanitation process to be quicker. You wanted to just retrofit this new gate into your existing SlipstickTriple/S Field Service Team had ideas about this new gate and set out to build one for our Test Lab. The new Eco-Gate is tool-less and opens from the side of the conveyor. One major food manufacturer retrofitted one Eco-Gate as a test and liked it so much they installed 15 more!

Visit at

verb - to install (new parts) in something previously manufactured or constructed

C A L E N D A R

September 2015 | Food Engineering | www.foodengineeringmag.com

OCTOBER 201519-21: PORK 101; Iowa State University, Ames, IA; American Association of Meat

Processors, American Society of Animal Science, North American Meat Institute Foundation

and the Southwest Meat Association; 800-517-2672, ext. 12; www.meatscience.org

19-21: Basic HACCP: A Food Safety System; Da Vinci Building, Davis, CA; UC

Davis Extension; 800-752-0881; http://extension.ucdavis.edu/agriculture

23-25: PMA Fresh Summit Convention + Expo; Georgia World Congress Center,

Atlanta, GA; Produce Marketing Association; www.pma.com/events/freshsummit

NOVEMBER 20158-11: ProcessTechnologyXchange; The Westin Cape Coral Resort at Marina

Village, Cape Coral, FL; VerticalXchange; www.verticalxchange.com/xchanges/

processtechnologyxchange

DECEMBER 20152-3: Global Pouch West; Hyatt Regency Orange County, Garden Grove, CA; BNP

Media; 800-524-7225; www.globalpouchwest.com

JANUARY 201611-13: Northwest Food & Beverage Manufacturers Expo & Conference; Oregon Convention Center, Portland, OR; Northwest Food Processors Association; 503-

327-2200; www.nwfpa.org

26-28: 2016 International Poultry Expo/International Production & Processing Expo; Georgia World Congress Center, Atlanta, GA; U.S. Poultry & Egg

Association, American Feed Industry Association and North American Meat Institute;

678-514-1977; www.ippexpo.com

FEBRUARY 20168-11: 20th Annual ARC Industry Forum; Renaissance Orlando at SeaWorld,

Orlando, FL; ARC Advisory Group; 781-471-1175; www.arcweb.com/events/

arc-industry-forum-orlando

MARCH 201619-22: Snaxpo 2016; Houston, TX; Snack Food Association; 703-836-4500;

www.sfa.org

APRIL 20164-7: MODEX Show; Georgia World Congress Center, Atlanta, GA; MHI; 704-676-1190;

www.modexshow.com

10-13: Food Automation & Manufacturing Conference; Sanibel Harbour

Marriott, Fort Myers, FL; Food Engineering; www.foodautomationconference.com

2016

April 10-13, 2016Sanibel Harbour Marriott,

Ft. Myers, FL

www.foodautomationconference.com

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See Food Master, p. 114-115

C A L E N D A R

APRIL 201612-14: International Cheese Technology Exposition; Wisconsin Center,

Milwaukee, WI; Wisconsin Cheese Makers Association; www.cheeseexpo.org

MAY 20163-5: International Powder & Bulk Solids Conference and Exhibition; Donald

E. Stephens Convention Center, Rosemont, IL; UBM Canon; 310-445-8535; www.

canontradeshows.com/expo/ptxi14/htp.html

10-12: Food Safety Summit; Donald E. Stephens Convention Center, Rosemont, IL;

BNP Media; 847-405-4000; www.foodsafetysummit.com

17-20: EXPO PACK México 2016; Expo Bancomer Santa Fe, Mexico City, Mexico;

PMMI, The Association for Packaging and Processing Technologies;

www.expopack.com.mx

JULY 201616-19: IFT Annual Meeting & Food Expo; Chicago, IL; Institute of Food

Technologists; 312-782-8424; www.ift.org

OCTOBER 20168-11: International Baking Industry Exposition; Las Vegas Convention Center,

Las Vegas, NV; American Bakers Association and Baking Industry Suppliers Association;

www.ibie2016.com

NOVEMBER 20166-9: PACK EXPO International; McCormick Place, Chicago, IL; PMMI, The

Association for Packaging and Processing Technologies;

www.packexpointernational.com

FEBRUARY 201713-15: PACK EXPO East; Pennsylvania Convention Center, Philadelphia, PA;

PMMI, The Association for Packaging and Processing Technologies;

www.packexpoeast.com

MAY 20172-6: Metpack 2017; Essen, Germany; Messe Essen GmbH; www.metpack.de

4-10: interpack 2017; Düsseldorf, Germany; Messe Düsseldorf North America;

312-781-5180; www.mdna.com

JUNE 201713-15: EXPO PACK Guadalajara; Guadalajara, Jalisco, Mexico; PMMI, The

Association for Packaging and Processing Technologies;

www.expopackguadalajara.com.mx

25-28: IFT Annual Meeting & Food Expo; Sands Expo Center, Las Vegas, NV;

Institute of Food Technologists; 312-782-8424; www.ift.org

MARCH 201820-23: Anuga FoodTec; Cologne, Germany; Koelnmesse; +49 1806 578 866;

www.anugafoodtec.com

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Festo offers a complete range of products, systems and selected services for process automation and factory automation in the food and beverage industry.


“I’m really aproduction guy

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production challenges our customers face every day.

Ross Regional Sales Managers are all full-time, salaried experts who will

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N E W SM A N U F A C T U R I N G

Kraft Foods plans to spend $114 million to add 25,000 sq. ft. to its Columbia, MO plant, which makes Oscar Mayer hot dogs. The new facil-ity will begin production in 2016.

Mars Inc. is investing $100 million at its Topeka, KS chocolate plant to build an add-on, state-of-the-art 90,000-sq.-ft. manufacturing facility.

Hardywood Park Craft Brewery will invest more than $28 million to add 60,000 sq. ft. to its Richmond, VA facility for brewing, packaging, distri-bution and a retail center.

The New Hampshire Food Bank will open a 2,800-sq.-ft. processing plant within its 60,000-sq.-ft. distri-bution center in Manchester. The processing plant, which will accept donated produce from local farms and other donated ingredients, will be the first in Northeast and the second in the country run by a food bank. It will begin operation in six months, making packaged meals and other products to distribute to food pantries around the state.

Wisconsin-based Sargento Foods is investing $30 million to expand its production facility in Kiel by 80,000 sq. ft. and its technical center in Elkhart Lake by 59,000 sq. ft.

Good Foods Group LLC celebrated the expansion of its Pleasant Prairie, WI site, which added 40,000 sq. ft. to its facility in Lake View Corporate Park. The processor makes guaca-mole, cold-pressed juices and other foods.

PLANT OPENINGS & EXPANSIONS

n 2012, industry ( c o m -p r i s e d

o f m a n u -f a c t u r i n g , agr iculture, mini ng and construction) accounted for a b o u t o n e -t h i rd ( 3 0 . 6 quads) of the US’s total pri-mary energy consumption, according to a recently released DOE report entitled “Barriers to Industrial Energy Efficien-cy.” (A quad is equivalent to 1 quadrillion BTUs.)

In 2010, the food and beverage indus-try was the fifth-largest energy consumer (1.25 quads) in the manufacturing sub-sector. While the industrial sector has made steady progress in saving energy, the rate of adopting energy-efficient technol-ogies and practices could be accelerated to reduce energy consumption another 15 to 32 percent by 2025, according to the report. From 2002 through 2010, some heavy-duty industries significant-ly decreased their energy intensity (the measure of energy to produce a product). For example, the chemical industry and primary metals manufacturers saw the greatest decrease, while the food industry remained relatively flat during the same period (see graph).

Energy efficiency can be achieved across a diverse range of technologies such as:

• Motors—Retrofit existing motors

with VFDs; replace aging motors with modern, efficient versions.

• Steam systems—Retrofit existing boil-ers with economizers; improve steam trap maintenance.

• Plant buildings—Upgrade lighting (lamps and controls); improve HVAC maintenance.

• Process equipment—Enhance process monitoring through the use of sensors and controls; improve maintenance schedules and procedures for process equipment.

• Plan energy management systems—Adopt management practices and systems that optimize energy use across plant loca-tions; use enhanced data collection for more informed decisions that will drive down energy use; share results at all orga-

N E W SM A N U F A C T U R I N G

DOE lists barriers to saving energy

The graph shows the food sector as nearly level through the eight-year period. Sources: Energy consumption from MECS, 2010 and ICF Estimates; Industrial Production from Federal Reserve Board, Industrial Production Indices, 2014; DOE.

I Manufacturing delivered energy intensity by subsector, 2002-2010

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

105.0

110.0

2002 2006 2010

Inde

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Inte

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Non-metallic minerals

Petroleum and coal products

Total manufacturing

Primary metals

Chemicals

16

N E W S


M A N U F A C T U R I N G

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nizational levels to emphasize the impor-tance of achieving energy-saving goals.

According to the report, the ben-efits of implementing these strategies include reduced energ y and emis-sions control costs, plus enhanced competitiveness. Co-benefits include

economic, financial and regulatory barri-ers include:

• Internal competition for capital—Manufacturers have limited capital avail-able for projects and expect payback in one to three years.

• Corporate tax structures—Depre-ciation periods and the handling of energy bills can be a deterrent.

• Program planning cycles—Com-panies often split costs and benefits for energy projects between business units, complicating decision-making.

• Failing to recognize efficiency’s non-energy benefits results in under-procure-ment of energy-related resources.

• Energy price trends—Volatile energy prices create uncertainty in investment returns.

• Utility business model—Utilities lose interest in promoting energy-efficiency projects.

• Industrial participation in ratepayer-funded energy-efficiency programs—Opt-out or loosely defined self-direct programs keep manufacturers from par-ticipating in traditional energy-efficiency programs.

• Failing to recognize all the benefits of efficiency results in fewer implementa-tions.

• Energy resource planning—Energy efficiency should be considered as a part of the integrated resource planning process.

• Environmental permitting—Uncer-tainty, complexity and costs associated with permitting processes such as New Source Review (NSR) keep manufactur-ers from moving ahead.

The report also lists several informa-tional barriers that slow energy-saving implementations. For example, unaware-ness of federal, state and utility incentives; a lack of disaggregated energy consump-tion data (e.g., process unit, equipment level); many manufacturers lack in-house technical staff to develop energy-saving projects.

Download the study at http://www.energy.gov/sites/prod/files/2015/06/f 2 3 / E X EC - 2 0 1 4 - 0 0 5 8 4 6 _ 5 % 2 0Study__0.pdf.

reduced mater ia l loss , improved product quality and reduced water consumption.

Manufacturers have shown progress in using energy more efficiently. However, barriers still impede greater implementa-tion of energy-reduction techniques. The


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REGULATORY WATCH

Industry ready to do business with CubaMany US food producers and manufac-turers have expressed support for the renewal of diplomatic ties with Cuba. While the Obama Administration has established official ties to Havana, Republicans in Congress have gener-ally balked at the idea of lifting the trade embargo.

The North American Meat Insti-tute is among the trade groups urg-ing a lifting of the embargo, saying it supports a bill pending in Congress that would remove the current pro-hibition against private financing for agricultural sales to Cuba.

Devry Boughner Vorwerk, a Cargill executive who is chair of the US Agricul-ture Coalition for Cuba, says agribusi-ness is firmly in the camp for lifting the trade embargo.

New proposed rule for Nutrition Facts label FDA has issued a supplemental pro-posed rule that would make two minor changes to the Nutrition Facts label on food products: It would require declara-tion of the percent daily value (%DV) for added sugars and change the current footnote on the Nutrition Facts label.

FDA says the percent daily value indicates how much of a nutrient in a serving of food contributes to a daily diet and would help consumers make informed choices for themselves and their families. The percent daily value would be based on the recommenda-tion that the daily intake of calories from added sugars not exceed 10 per-cent of total calories.

The change to the footnote on the label would shorten the current wording.

GMA supports federal approach to food labelingThe US House of Representatives

approved the Safe and Accurate Food Labeling Act by a vote of 275 to 150 and moved the legislation to the Sen-ate. The measure would establish a single, unified standard for food to be labeled “GMO free,” preempting vari-ous state laws.

“A federal approach to food labeling remains the only way to ensure Ameri-cans everywhere can access accurate information about the food they pur-chase,” says Pamela Bailey, president and CEO of the Grocery Manufacturers Association.

18

N E W S


M A N U F A C T U R I N G

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Bolthouse Farms appointed Scott LaPorta as president and general manager.

MOCON named Michael Barto vice president of engineering and manufac-turing.

OMRON Corporation has acquired a 100 percent stake in Delta Tau Data Systems, Inc.

Zeljko Pockaj was named managing director of Romaco Innojet.

INDUSTRY & PEOPLEDorner Manu-facturing Group appointed Dan Nasato vice presi-dent—international operations.

Ipack-Ima CEO Guido Corbella announced his retire-ment.

Pat Graef was named president of ASHRAE.

Peacock Engineer-ing acquired L&L Foods.

Mitsubishi Heavy Industries and Mitsubishi Nichiyu Forklift will purchase UniCarriers Corporation.

Thomas DiGiannurio was promoted to vice president of engineer-ing at Charles Ross & Son Company.

Stellar completed its design-build of the $50 million Nestlé Global R&D Center for the advancement of frozen and chilled foods.

Adept Technology, Inc. hired Brian McMorris as vice president of North American sales for fixed robotics.

ProSoft Technology named Joe Rick senior director of North America sales.

Fristam Pumps hired Jim McCoy as sales manager.

David Dixon joined Faithful+Gould as program director for the food and beverage and consumer packaged goods subsector.

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F O O D P A C K A G I N GDebra Schug, Features Editor

Pushing away from petroleumCoca-Cola unveils the first 100 percent plant-based PET bottle and begins work on its commercialization.

A s more companies continue to beef up their sustainable manufacturing prac-tices, Coca-Cola has introduced a PET plastic bottle made entirely from sug-

arcane. The company’s PlantBottle technology is designed to reduce the amount of petroleum used in packaging, replacing it with a more sustainable alternative that is fully recyclable.

“PlantBottle packaging is reducing our depen-dence on fossil fuel and increasing our use of renewable materials,” says Mackenzie Anderson, environmental communications manager for Coca-Cola. “We focus on delivering the quality beverages our consumers expect in the most efficient way pos-sible, with a key focus on recyclability, minimizing resources and increasing the use of recycled and renewable materials.”

PlantBottle packaging was introduced in 2009 as part of the company’s vision to develop more responsible packaging. Its production involves converting natural sugars found in plants into the ingredients for making PET plastic bottles. Over 35 billion PlantBottles in the currently available version, which is made from up to 30 percent plant-

based materials, have been distributed in nearly 40 countries. The company estimates the technology has eliminated more than 315,000 metric tons of carbon dioxide emissions and saved more than 36 million gallons of gas.

“We know natural resources are stressed, and com-munities are forced to do more with less,” Anderson says. “Since our packaging is the last interaction we have with our consumers, it needs to remind them of our commitment to sustainability.”

Introduced at the most recent World Expo in Milan, Italy, the 100 percent plant-based bottles are not ready to be shipped just yet. The company is working on a sustainable, commercial solution to distribute the bottles in more than 200 countries.

“ We announced agreements with three bio-technology firms to support the move from lab to commercial scale,” says Anderson. “These three companies will help us make a significant step toward reaching our goal of commercializing Plant-Bottle packaging made entirely from plant-based materials with the next few years.”

In a larger effort, Coca-Cola has partnered with a number of companies, such as H.J. Heinz and Procter & Gamble, to form the Plant PET Technology Collaborative. This organization supports research to enable commercially viable, sustainably sourced, 100 percent plant-based PET plastic. The company is also a member of the Bio-plastic Feedstock Alliance, which was formed to help companies responsibly select feedstocks for biobased plastics.

Additionally, Liquid Light, a process technology company that makes chemicals from carbon diox-ide, recently signed an agreement with The Coca-Cola Company to develop a more efficient way to use plant materials to make mono-ethylene glycol (MEG). MEG is one of the components used to make the plant-based PET plastic bottle. ❖

For more information:Katherine Schermerhorn, 404-676-2683, [email protected], www.coca-colacompany.com/plantbottle-technology.

Coca-Cola’s 100 percent plant-based PET bottle is made from renewable, responsibly sourced materials and is fully recyclable. Source: The Coca-Cola

Company.

22

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


iquid water enhancers allow con-sumers to flavor their water using a concentrated formula. The category is only four years old, but it is quickly

becoming crowded and competitive. That is why Brite Idea Foods wanted a unique pack-age—squeezeable with one hand and offering no-drip dispensing—for its all-natural H2wOw water enhancer.

Company Co-founder Tim Welch told Berlin Packaging and its Studio One Eleven design agency that the packaging needed to have a “fresh fruit feeling” to communi-cate H2wOw’s category-first use of real fruit extracts and other natural ingredients. The final design—small enough to throw into a purse or a gym bag—marries a curvy 2.1-fl.-oz. HDPE monolayer bottle manufactured from a custom Berlin Packag-ing mold with an Aptar Group stock flip-top Mini Sense PP closure and a full-body, tamper-evident shrink sleeve decorated to showcase the fresh message.

The bottle is palm-sized and features a pinched waist, giving H2wOw a distinctive shape. The closure incorporates an Aptar SimpliSqueeze silicone flow control valve to deliver spill-proof

use and protect against leakage, even when the cap is left open. The bottle and closure are sourced and supplied by Berlin

Packaging. The label is supplied by Century Labels of Bowling Green, OH. ❖

For more information: Andrew L. Gilbert, 978-462-0604, [email protected], www.berlinpackaging.com.

Feeling fresh

H2wOw label graphics are dominated by images of the fresh-cut fruits and vegetables in the Ginger Lime, Lemon Spearmint, Mandarin Grapefruit and Cucumber Lemongrass flavors. Source:

Berlin Packaging.

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while cutting costs and protecting the environment. (Tri-Seal is a division of Tekni-Plex, Inc.)

Tin/Saran barrier liners are more commonly used for ROPP wine applications, but the new liner is a cheaper, environmen-tally friendly option that can easily replace them. Permeation tests were conducted by an independent laboratory to compare the performance of the laminated aluminum foil/foam barrier liner with that of alternate materials currently in use. In addi-tion, the Australian Wine Research Institute carried out sensory organoleptic testing on the Tri-Vin liner.

“We invested significant resources to develop a cost-effective wine liner with the performance characteristics of tin/Saran lin-ers, while preserving the wine’s aroma and taste,” explains David Andrulonis, vice president and general manager of Tekni-Plex.

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For more information: David Andrulonis, Tekni-Plex, Inc., 419-491-2402, [email protected], www.tekni-films.com.

An aluminum foil/foam lamination has been engineered to replace the tin/Saran barrier liners commonly used for ROPP wine applications. Source: Tekni-Plex.

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F O O D S A F E T Y

Time to use some common-sense protocols

t’s a sad fact that some food processors still buy equipment based simply on price and the abil-ity to produce a product. But, cleanability, ease of maintenance, safe operation, user friendli-

ness and other factors should be considered when purchasing equipment.

The American Meat Institute assembled an expert panel a few years ago and developed 10 basic prin-ciples of the sanitary design of equipment used for ready-to-eat products:

1. Cleanable to a microbiological level2. Made of compatible materials 3. Accessible for inspection, maintenance, cleaning and sanitation4. No product or liquid collection5. Hermetically sealed hollow areas6. No niches 7. Sanitary operational performance8. Hygienic design of maintenance enclosures9. Hygienic compatibility with other plant systems10. Validated cleaning and sanitizing protocols.However, these principles apply to all food pro-

cessing equipment, not just those pieces used for ready-to-eat goods.

AMI’s website includes a checklist for evaluating equipment that can be accessed at https://www.meat-institute.org/ht/a/GetDocumentAction/i/97261. Each of the above 10 points has five to 15 sub-ele-ments. For example, validated cleaning and sanitiz-ing protocols include:

• Cleaning and sanitizing are considered in the design process.

• Cleaning protocols must be safe, practical, effec-tive and efficient.

• Cleaning and sanitat ion protocols have been developed by the manufacturer, validated and provided in a training manual that is easily read and understood by cleaning and sanitation employees.

• Equipment design and materials are capable of withstanding standard cleanup procedures, and the MSDSs for the cleaning and sanitizing chemicals have been reviewed to ensure compatibility. Special deep-cleaning should be scheduled based on indicators such as mean time failure analysis.

• All equipment components including belts and product contact components should be able to with-stand heating to 160˚F for up to 30 minutes. Proce-dures to protect sensitive components included in the manufacturer’s procedures should be followed.

One of the basic requirements for many companies is a mandate that a third party must approve their equipment for use in food processing. USDA evalu-ates equipment used in meat and poultry operations. Organizations such as 3A Sanitary Standards (http://www.3-a.org/) and EHEDG (European Hygienic Engineering and Design Group) (http://www.ehedg.org/) have established sanitary and hygienic stan-dards for equipment and list those that pass muster.

However, there is a basic issue that goes beyond san-itary design—program maintenance. Buying equip-ment that is easy to clean and maintain is only part of the equation; the programs to properly maintain and clean equipment must be scrupulously adhered to. In addition, managers must ensure these programs are properly developed, documented, implemented and maintained. This also includes sufficiently training staff to do the work and documenting the training was not only completed, but the staff members fully understand what they are doing and why.

In addition, food processors should establish basic guidelines for evaluating and purchasing new equip-ment. Setting up the program is part of the food safety management system and should also be part of the organization’s continuous improvement program. In fact, the program should be all inclusive when it comes to food processing and handling equipment. Every change or tweak to equipment should be evalu-

Food and beverage processors should commit to properly evaluating equipment and process changes by doing it right the first time around.

Richard F. Stier,Contributing Editor

I

28

F O O D S A F E T Y


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ated prior to making it. Far too often, companies make changes in line layout or operations only to learn they have had an adverse effect on food quality, food safety or operational efficiencies.

A wise processor will set up a program to take an in-depth look at any change to processing operations, whether it is a tweak or a new equipment purchase. Subjecting any change to a rigid evalu-ation before it is made will determine whether it will be feasible and effective.

If management decides the plant requires new equipment to meet the needs of existing or new customers or as a means of enhancing quality and safety programs, the following procedures should be followed:

• Top management should review the need for change with key plant and management personnel (treasurer, production man-ager, quality supervisor and the food safety team or a designated member) and discuss options for improvement. Notes of the meeting should be maintained.

• Management should assign staff to research equipment, materials or proposed changes to ensure they meet the needs of the plant. This research would include identifying potential equipment and suppliers, and how the changes would be made. This step is where the FMEA concept comes in handy; if the results of the FMEA indicate a potential change poses a potential risk to the business, that option would be eliminated or modified to address the identified risks.

• Once the equipment has been selected, the team should review specifications and pricing, and rate the materials. Notes of this meeting should be maintained.

• An individual should be designated to visit one or more facili-ties that use the equipment or materials to evaluate performance. Notes from the trip should be prepared and filed. (This is often a challenge since an individual may not be allowed into a com-petitor’s facility.) The focus of this exercise is to not only select the right equipment but to ensure the equipment will pose no significant risks to the business.

Some companies take this process a bit further. Instead of accepting what the equipment manufacturer offers, they work hand-in-hand with the company to further improve the exist-ing equipment. These tweaks then become the property of the food processor.

All of this may seem like a great deal of effort, but going through this process is worth it. Equipment that meets the 10 previously highlighted principles, and is easy to operate, maintain and clean, can provide significant economic benefits such as improved operating efficiencies, reduced operating costs and enhanced product quality. However, managers must ensure the established systems are adequately maintained. Food and beverage processors should commit to properly evaluating equipment and process changes by doing it right the first time around. ❖

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FIBER LASER CODERS Delivering a fine spot size for permanent codes, Linx fiber laser cod-ers are suitable for a variety of materials used in static applications and moving production lines. They produce small, discreet codes for traceability or anti-counterfeiting purposes, bigger codes for high-profile branding or promotions and large amounts of information in a small area. The coders feature a range of fonts, codes and graphics.Linx Printing Technologies Ltd; www.linxglobal.com

LARGE-TUBE MAGNETIC SEPARATOR Engineered for high-flow liquid processing applications, the IMI T-Trap magnetic separator has 1 large-tube magnet that provides direct, in-the-flow contact of the product to the magnetic tube. The separator is typically placed in front of pumps, screens and mills to ensure product purity and protect plant equipment. Available in 1 1/2- to 6-in. line sizes, the unit can be installed in horizontal, verti-cal or sloped line orientations. It is intended for liquids, purées and products that may contain small solids, such as juices, applesauce or cottage cheese. Industrial Magnetics, Inc.; 231-582-3100; www.magnetics.com

PALLET TRUCKThe Raymond Model 8210 walkie pallet truck features AC technol-ogy, static torque control, a ductile iron frame and undercarriage components, and stainless steel undercarriage pins. It comes stan-dard with IP65 protection of its electronics; a range of options for harsh environments is available.The Raymond Corporation; 800-235-7200; www.ray-mondcorp.com

TANK TOP BEARINGSHercules Engineering Herculon Type D tank top bearings are installed under the roof beams of tank tops and other lighter structures in the food and beverage industries to support them and prevent them from cracking and breaking. The bearings consist of a thin, stainless steel slide plate with 2 stainless steel studs flash welded to the upper face. The plate has 2 slotted holes for uplift through-bolts.Hercules Engineering; www.hercules-engineering.com


S O U R C E B O O K

T E C H N O L O G Y

2672 S. La Cienega Blvd Los Angeles, CA 90034 USA

(800) 336-1942 (310) 839-2828 www.tek leen.com [email protected]

Why should you filter your water?Tekleen Filters will save you time and money spent every day in the labor of cleaning and replacing screens, spraying nozzles, spraying bars, heat exchangers, sand media tanks, sprinklers and many more.

SORTING, PEELING & PROCESS ANALYTICS SOLUTIONS FOR THE FOOD INDUSTRY

TOMRA Sorting Solutions is a leading provider of sensor- based food sorting machines and food processing technology for the fresh and processed food industries. Developing state-of-the-art technologies, optimizing customers’ production flow and helping to deliver consistent high quality food have been TOMRA’s strengths for more than 40 years.

www.tomra.com/food [email protected]

VISIT US AT PACK EXPO 2015

BOOTH S-8033

INVERTING FILTER CENTRIFUGE The Heinkel inverting filter centrifuge features an axially moveable filter cloth that can be inverted while under rotation; the filter cloth remains free of residual cake heel while a totally enclosed, gastight system is maintained. Capable of thin cake filtering and direct contact drying of the material, the centrifuge provides homogenous cake structure and automatic cake discharge.Heinkel USA; 856-467-3399; www.heinkelusa.com

S O U R C E B O O K

T E C H N O L O G Y

RE7RARE EARTH MAGNETIC SEPARATORS

Rare EarthMAGNETIC SEPARATORS

®New!New!

See Head-to-Head Comparisons! Booth S-5901

Booth 6200®

RE7RARE EARTH MAGNETIC SEPARATORS

Rare EarthMAGNETIC SEPARATORS

®New!New!

See Head-to-Head Comparisons! Booth S-5901

Booth 6200®

PNEUMATIC CYLINDERS Constructed with an extruded aluminum body, Bimba MFD compact double-acting pneumatic cylinders come in 10 bore sizes and a range of standard stroke lengths; they are available with a magnetic piston to enhance position sensing. Suitable for a variety of automation processes, the cylinders are globally interchangeable with industry alternatives.Bimba Manufacturing Company; www.bimba.com

MULTI-SPECTRUM METAL DETECTOR Able to detect smaller particle sizes of ferrous, non-ferrous and AISI 316 stainless steel, the CEIA THS/MS21 multi-spectrum metal detec-tor eliminates false rejects caused by product effect conditions. The auto-learn system selects, displays and stores the optimal sensitivity settings for hundreds of products. The metal detector has an IP69K rating for high-pressure, high-temperature washdown protection.Heat and Control, Inc.; 800-227-5980; www.heatandcontrol.com

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To continually improve separation quality, Eriez designed its new RE7 Xtreme® Rare Earth magnetic separators to extract fine ferrous material and even work-hardened stainless steel from product flows. Eriez employed sophisticated finite element analysis to produce this incredibly powerful magnetic circuit intended for applications demanding the highest levels of product purity.

When only the Strongest Magnet will do!

Purity.Eriez.com 888.300.3743

To continually improve separation quality, Eriez designed its new RE7 Xtreme® Rare Earth magnetic separators to extract fine ferrous material and even work-hardened stainless steel from product flows. Eriez employed sophisticated finite element analysis to produce this incredibly powerful magnetic circuit intended for applications demanding the highest levels of product purity.

When only the Strongest Magnet will do!

Purity.Eriez.com 888.300.3743

Strongest Magne

magnetic circuit intended for applications demanding the highest levels of product purity.

Purity.Eriez.com

ROTARY HEAD BELT WASHER The Douglas Cyclone rotary head belt washer washes and removes allergens from belts. Designed for a variety of open mesh spiral con-veyors, freezer tunnels and oven belts, the unit has a spray head with high-pressure rotating nozzles that cut and remove stubborn soils from the top and bottom of a belt simultaneously. A portable cart allows the washer to be moved from 1 belt to another. Douglas Machines Corp.; 727-461-3477; www.dougmac.com

WASHDOWN CHECKWEIGHER Featuring production monitoring and control, the METTLER TOLEDO C3572 checkweigher incorporates stainless steel conveyors with an open, accessible frame design. Built for food production areas with heavy washdown requirements, it offers a weighing range up to 4,000g with an accuracy of +/-200mg at speeds up to 300 ppm. Standard features include electromagnetic force restoration weigh cell technology and a conveyor support structure with 4 solid tubes. Optional infeed timing and spacing conveyors, reject mechanisms and stainless steel locking reject bins are available.METTLER TOLEDO Hi-Speed; www.mt.com/hi-speed


S O U R C E B O O K

T E C H N O L O G Y

888.582.0821 ~ www.magnetics.com

STRONGEST MAGNETIC TUBE DESIGNIN THE INDUSTRY

We utilize the strongest, most stable, commercially available magnet material

in our Industry leading metal separation products to

provide the most effective magnetic separation solutions available.

FEATURING

52 MGOERARE EARTH MAGNET MATERIAL

THE BULLET® MAGNET(PNEUMATIC LINE SEPARATION MAGNET)

METAL DETECTOR CONVEYORS Sesotec Rapicon metal detector conveyors include modular components, standard reject systems and a range of aperture sizes. A fully welded construction, combined with GHF or GLS metal detection technology, provides a food-safe platform and the detection of small pieces of metal.Sesotec Inc.; 224-208-1900; www.sesotec.us

CHECKWEIGHER/METAL DETECTORS Anritsu CW and MD systems combine checkweighing and metal detection in 1 package; they provide the 2 functions simul-taneously. The integrated checkweigher han-

dles hundreds of products per minute with a potential accuracy of +/-.01g, depending on the application. Adopting a 2-frequency magnetization detection method, the sys-tems detect ferrous and stainless metals at the same time, independent of each other.Anritsu; www.detectionperfection.com

ULTRASONIC CLEANER With a 24-gal. main tank capacity and horizontal transducers, the Ultrasonic Ultra 2400FA ultrasonic cleaner requires no sol-vents. It features an agitation table, dual filtration, 6-gal. weir tank, sparge bar and insulated tank and lid; the side-mounted transducers eliminate dead spots for consis-tent cleaning. The cleaner offers 1,920W of ultrasonic power and a 22- x 11- x 5 1/2-in. basket capacity. A 7-day heat and auxiliary timer allows programming to suit production requirements.Ultrasonic LLC; www.ultrasonicllc.com

www.foodengineeringmag.com | Food Engineering | September 2015

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METAL DETECTOR Manufactured for challenging applications, the Fortress Interceptor NEMA 4X-/IP69K-rated metal detector uses a simultaneous multi-frequency operation that processes the transmission and recep-tion of multiple frequencies continuously over a broad spectrum. Constructed of stainless steel, it features ARM processors, a noise-immunity structure, single-pass product “learn,” automatic product tracing and contact reporter software. Typical applications include bakery, meats, dairy, prepared meals, confectionery, fresh foods, frozen foods, powders and grains.Fortress Technology Inc.; 888-220-8737; www.fortresstechnology.com

BELT CLEANING SYSTEMThe AmeriVap Houdini jet system automatically cleans continuous mesh interlocking belts while they are in operation; it dislodges any accumulated debris and sanitizes with super-heated saturated dry steam vapor. Designed as a portable solution, the unit is constructed with corrosion-resistant materials and a water-resistant stainless steel enclosure. It is powered by an industrial steam generator that continuously delivers 150 psi.AmeriVap Systems, Inc.; 800-763-7687; www.amerivap.com

MEASUREMENT/DETECTION SOLUTIONDesigned as a multi-application system, the Eagle FA3/M inline fat measurement and contaminant detection solution handles various forms of meat product including fresh, hot-boned, chilled and frozen. It uses dual energy X-ray absorptiometry technology to discriminate between fat and lean in meat products with 100% throughput. When used in collaboration with Eagle SimulTask inspection software, the system can inspect over 2,400 plastic crates or frozen blocks per hour or up to 35 tons of bulk meat per hour.Eagle Product Inspection; www.eaglepi.com

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DATA LOGGERS Compact and portable, Omega OM-90 series data loggers feature an immediate, delayed (specific date/time) or pushbutton start; a real-time mode; user-configurable high and low alarms; LED status indicators; and a USB interface for data transfer. The OM-91 version is used to log temperature, while the OM-92 model logs temperature and relative humidity.Omega; 800-TC-OMEGA

WIRELESS PRESSURE TRANSMITTERDesigned to connect wirelessly to virtu-ally any iPhone or iPad, the GP:50 iDucer Bluetooth wireless pressure transmitter measures pressure values from 0 to 1 psi through 0 to 30,000 psi with +/-0.2% FSO standard accuracy. The supplied iOS application software allows all collected data to be downloaded, analyzed and stored for future use. The unit features all-stainless steel wetted parts and hous-ings, as well as 1/4-in. NPT (M) standard process connections.GP:50 NY LTD; 877-774-4781; www.gp50.com

LOW-LINT CLEANING CLOTH Designed for lint and static electricity-sensitive industries such as food processing, the SCA Tork industrial low-lint cleaning cloth is used for cleaning, sanitizing and disinfecting surfaces, tools and equipment. It offers absorbency for working with water, solvents, sanitizers and dis-infectants. SCA; www.sca.com/us

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Efficient and durable utility heating

Alfa Laval has the most complete range of gasketed plate heat exchangers (GPHE), from potable water or glycol heating and cooling to hygienic hot water sets. All GPHE’s are backed by our leading technology and support.

• Alfa Laval M-Series is an efficient solution for general heating and cooling in hygienic applications. It’s also the perfect alternative for heating and cooling service media.

• Alfa Laval TS6 is designed exclusively for steam-to-liquid heating. The unique plate geometry, combined with heavy-duty gaskets, makes it ideal for heating water or cleaning-in-place solution.

See our complete range of heat exchangers: www.alfalaval.com/gphe-us

TANK WASHING NOZZLE The BEX TWK molded tank washing noz-zle provides 360° and 180° rotation in a PVDF construction. Operating at up to 80 psi, the self-lubricating nozzle is suitable for vessels up to 10 ft. in diameter. The nozzle flow ranges from 1.77 gal./min. at 5 psi to over 7 gal. at 80 psi. Able to be installed in any orientation, the nozzle can be used for keg and tank washing, small tank rinsing, machine clean-in-place and food processing applications.BEX Incorporated; 734-389-0464; www.bex.com

MULTI-TOUCH PANEL PCs Beckhoff CP32xx industrial multi-touch panel PCs automate HMI and control applications. Engineered for mounting arm installation, they feature all-around IP65 protection. The connecting cables are laid through the support arm into the connection compartment for up to 6 IP65-rated connectors. In the basic con-figuration, 2 of the connection points are configured with an Ethernet interface or power supply; the remainder are option-ally available for a mini-PCI fieldbus interface or a further Ethernet, USB or serial interface.Beckhoff Automation LLC; 877-Twin-CAT; www.beckhoffautomation.com

TRAPPED KEY INTERLOCKS Enhancing lockout/tagout procedures, KIRK trapped key interlocks ensure energy isolation procedures cannot be circumvented. Once the key is removed from the interlock, the equipment cannot be re-energized until the uniquely coded KIRK key is re-entered into the sequence. A time delay unit can be added to allow hazardous energy to dissipate prior to allowing access.Kirk; 800-438-2442; www.kirkkey.com

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800.749.5823

SummitIndustrial Products

www.klsummit.com www.sublimedescaler.com 903.534.8021

Summit’s FG Elite is a combination of synthetic base fluidsand additives engineered for the increased performance offood industry rotary screw, rotary vane and reciprocating aircompressors. Summit’s FG Elite lubricant benefits include:

• Up to 10,000 hours depending on operating conditions• Increased solvency reduces deposit and sludge formation• Superior protection against rust, wear and corrosion• Meets the requirements of NSF H1 registered lubricants• Manufactured in an ISO 21469 certified production facility• ISO Viscosity Grades of 32, 46, 68, 100 and 150

FG EliteExtended LifeFood Grade

Air Compressor Oil

Up to 10,000 hours of Dependable Service

MULTI-SHAFT MIXER Featuring a 2-wing anchor, gate agitator and high-speed disperser, the Ross VersaMix Model VMC-1000 multi-shaft mixer has a 1,000-gal. working capacity. Each agitator is independently driven, imparting a range of mixing intensities and flow patterns as the product changes rheologically through-out the batching cycle. An air/oil hydraulic lift raises and lowers the entire agitator assembly. The mixer rotates 90° and can be raised or lowered for cleaning and servicing. Built for atmospheric or vacuum/pressure operation, it is available with options such as a jacketed vessel, powder loading chute, sight ports, automated discharge valves, tank lights, thermoprobes, a temperature control unit, vacuum pump, discharge system and PLC recipe controls.Charles Ross & Son Company; 800-243-ROSS; www.mixers.com

AIR SYSTEM MANAGERA master control system for all compressed air production and treatment components, the Kaeser Sigma Air Manager 2 unit opti-mizes pressure values, automatically adjusts system air delivery to accommodate fluctuat-ing air demand and constantly analyzes the relationship between control losses, switch-ing losses and pressure flexibility. Built-in maintenance reminders and messaging capabilities enable predictive maintenance.Kaeser Compressors; 877-586-2691

FILM SPLICERUsed in printing and packaging applications, the Butler Automatic 1000 Series automatic film splicer run at speeds up to 1,400 ft./min. and can handle non-woven substrates up to 64-in. wide without interrupting production. It features a roll-over-roll design and does not require a pit for installation. Butler Automatic; 508-923-0544; www.butlerautomatic.com

� Storage Tanks� Batch & Blending Systems� VacuShear Mixing Systems� Balance Tanks� CiP Tanks� Hold Tubes� HTST Systems (Modules)� CIP Systems� Transfer Panels� Melt Systems� Modular Process Systems� Platforms� Piping Installation Services

compliant process/storage vessel designs

Please call 888.258.2789 or visit us at

www.abprocess.com for a virtual tour of our campus

A&B provides exceptional concept to completionservices however we also provide the same exceptional service to clients retrofitting or expanding an existing system.

Whether you need a small single tank, a transferpanel, or any single component A&B is here to help!

We will work closely with you to make sure your expansion or update is seamless.

Our outstanding staff of designers and engineerswill take the time to understand your needs and provide you innovative and cost-effective solutions.

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Metal Detection

Machine Vision

X-ray Inspection

ConnectivityCheckweighing

See live demonstrations on new equipment in Booth C1814!

Trust the Product Inspection Industry LeadersMETTLER TOLEDO helps manufacturers ensure product quality, increase productivity, and protect their customers and brand.

4www.mt.com/pius-packexpo

PACKAGINGPROCESSINGONEPOWERFULSHOW.

PACK EXPO InternationalSeptember 28-30, 2015Las Vegas Convention Center

Booth # C1814

BLAST CHILLERSFloor standing models, Master-Bilt reach-in blast chillers are designed for high-capacity input. Each exterior wall is 2.95-in. thick. The MBC80-8A model chills 80 lb. of product, while the MBC113-6A version chills 113 lb. of product, from 194°F to 37°F in 90 min.Master-Bilt; 800-647-1284; www.master-bilt.com

TANK CLEANING NOZZLE Designed for the food and beverage indus-try, the Lechler XactClean HP tank cleaning nozzle features controlled rotation. The flat fan nozzles provide high-impact, uniform cleaning to remove difficult soils. The nozzle can operate in any direction. Lechler Inc.; 800-777-2926; www.lech-lerusa.com

INDUSTRIAL ROUTERThe KEB COMBICONTROL Ethernet-based C6 industrial router comes with WAN, LAN, USB and serial interfaces, as well as stan-dard digital I/Os; for hard-to-access instal-lations, a cellular network option is available. The router includes standard 2G/3G/3G+ EDGE/HSPA quadriband capable of speeds up to 5Mbps up/14Mbps down. The unit is housed in a stainless steel enclosure ready for DIN rail or wall mount.KEB America, Inc.; www.kebamerica.com

BOWL CUTTERThe TIPPER TIE TTChop33 industrial bowl cutter features a 330L bowl size, AC motor, integrated stainless steel switch cabinet and an ejector with an inexpensive wear ring. Suitable for midrange production, it is avail-able with vacuum, a cooking function and CO2 or nitrogen cooling capability. TIPPER TIE, Inc.; 919-362-8811; www.tippertie.com

Visit Us at Booth 7401210.736.1811 • www.meyer-industries.com

3528 Fredericksburg Rd. San Antonio, TX 78201

Sanitary Belt ConveyorS

reduCeClean-Up time

proven Design. Durable Construction.Meyer Sanitary Belt Conveyors combine proven designs with durable, highly

sanitary construction that results in a dramatic reduction in clean up time

compared to modular belting.

Highly Sanitary. time-tested Results.ideal for heavy wash down environments, these units are available in a wide

range of sizes and configurations to accommodate the inspection, storing or

transporting of products.

Vibratory Conveyors Bucket elevatorsSanitary Belt Conveyors Vibratory Weighers

Contact Meyer industries today for more information on all their bulk material handling and food processing equipment.

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Smarter. With features such as quick changeover, optional Ultrasonic sealing, and integrated zipper applicators, Triangle’s X-Series VFFS baggers are nothing short of brilliant. Cleaner design. Faster production. Built for the standards the industry and your customers demand, and backed by the best service and support team.

800.621.4170www.trianglepackage.com

See Us at Pack Expo Las Vegas • Booth 2620

SmarterBagging.

the X-Series VFFS Baggers

scan this code with your smartphone

ROTARY JET MIXER Able to handle liquid and powder mixing, gas dispersion and tank cleaning-in-place applications, the Alfa Laval rotary jet mixer can be used in tanks between 100 and 800,000L in size. Equipped with 2 or 4 nozzles, the mixer is positioned below the liquid level in a tank. Liquid is withdrawn from the tank outlet by a pump and circulated via an external loop to the mixer.Alfa Laval; www.alfalaval.com

LINEAR ACTUATOR Providing an advanced positioning capability, the Duff-Norton CMLA lin-ear actuator features IP66 protection for interior and exterior applications, a stainless steel translating tube for corrosion resistance, an anti-rotational outer tube and lightweight cast alumi-num housing. It comes in configura-tions from 500 to 2,000 lb. The motors are available in single- and 3-phase AC voltages, paired with a selection of gearing in each load category to provide a range of lifting speeds.Duff-Norton; 800-477-5002; www.duffnorton.com

INDUSTRIAL PRINTER The SATO CL4/6NX-J series Internet of Things label printer features universal functionality and design with plug-and-play connectivity and multiple languages. Compatible with the SATO Online Services cloud-based maintenance solution, it offers remote monitoring and preventative maintenance.SATO; www.satoworldwide.com

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SINCE // 1855

WWW.WEITZ.COM

DELIVERING INTEGRATED PROJECT SOLUTIONSServing the food and beverage industry with an

innovative and integrated team working together early in the design phase and throughout the

life-cycle of the project.

FORM/FILL/SEAL BAGGER Built for the snack food sector, the BVR 230 VFFS continuous vertical form/fill/seal bagging machine includes an integrated weigher, rotating sealing tool arrangement and separately driven cutting knife. Compat-ible with a range of film qualities, it produces up to 180 pillow bags/min.Rovema GmbH; www.rovema.com

TANK CLEANERAble to remove stubborn residues from vats, blenders, tanks and more, the Spraying Sys-tems TankJet 360 high-impact tank cleaner is suitable for vessels up to 100 ft. in diam-eter. The solid stream nozzles rotate 360° in horizontal and vertical planes to create a crisscrossing pattern that cleans all the interior surfaces; dual- or triple-nozzle hubs are available. Designed for permanent or CIP installation, the cleaner includes a built-in strainer and fits in vessels with openings as small as 6 1/4 in. (for the dual-nozzle version) and 10 1/4 in. (for the triple-nozzle model). Spraying Systems Co.; 800-95-SPRAY; www.spray.com

MAGNET ASSEMBLIESSuitable for applications where a surface is easily marred, Winco RoHS-compliant GN 51.6 steel-retaining magnet assemblies are comprised of a shielded magnetic assembly with a black elastomer (TPE) jacket and 2 internal threads. The magnet housing is made of zinc-plated steel, while the magnet is made of neodymium, iron and boron (NdFeB).J.W. Winco, Inc.; 800-877-8351; www.jwwinco.com

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As one of the most robust ERP solutions on the market, IFS Applications™ makes it possible to maintain a real-time awareness of your manufacturing operations. IFS Applications™ has the detailed reporting, production and planning functions you need to track everything, everywhere.

IFS-FOR AGILE BUSINESSwww.IFSWORLD.com

IFS APPLICATIONS IS.

PROCESS MANUFACTURING IS COMPLICATED. IS YOUR ERP SOLUTION UP TO THE TASK?

Visit IFS at PACK Expo, Booth S-8394

POLYPROPYLENE PACKAGING With the same inside food space as a 9- x 9-in. foam clamshell, Anchor Culinary Squares packaging includes clear polypropyl-ene vented lids with matching 8 1/2-in. square, black polypro-pylene bases; the lids and bases are both available in single and 3-compartment designs. They withstand temperatures up to 230°F.Anchor Packaging, Inc.; 800-467-3900; www.anchorpac.com

HARD SURFACE DISINFECTANT EPA registered for food contact surfaces, PURE hard surface dis-infectant and sanitizer incorporates a non-toxic, environmentally friendly SDC antimicrobial molecule. The product eliminates bacte-ria, viruses and fungi, including multiple drug-resistant organisms, norovirus, hepatitis B and C, Listeria, E. coli and Salmonella, in as little as 30 seconds and offers 24-hr. protection. Non-caustic and non-irritating, the odorless, ready-to-use formula contains no bleach, ammonia, phosphates, phenols or VOC-emitting compounds.PURE Bioscience, Inc.; www.purebio.com

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BETTER DRYING, BLOW OFF & RINSING

ENERGY EFFICIENT DRYINGPaxton’s high efficiency blowers and air delivery devices improve

drying of cans and bottles for high quality labeling and coding,

while using 60 – 80% less energy, typically giving a one year ROI.

DUST & DEBRIS BLOW OFFPaxton’s powerful air delivery removes particulates, dust and debris efficiently

and effectively. And if static cling is an issue, Paxton’s Ionized Air Systems

dissipate the static then blast the debris away.

BOTTLE & CAN RINSINGNO WATER / COMPRESSED AIR

NEEDED

Paxton’s New Ionized Air System replaces both water rinsing and

compressed air rinsing, using less energy and no wasted resources.

All Paxton Air Systems are custom-engineered to maximize performance

and minimize energy usage.

All Paxton Blowers carry a full three year warranty. 800.441.7475 • PAXTONPRODUCTS.COM

BOOTH

C-3309

FLEXIBLE CONDUIT The AFC Cable Systems LIQUID-TUFF UL Splash Zone Liquidtight flexible conduit is made with a polyvinyl chloride jacket that inhibits bacteria growth and withstands bleach cleaning and sterilization. Designed to meet NSF 169 commercial food equipment standards for splash zones in food production areas, the conduit comes in steel and non-metallic versions. It is suitable for meat packing, food processing and poultry packing applications.AFC Cable Systems, Inc.; www.afcweb.com

MAGNETIC SEPARATORS Suitable for practically any food processing application, Eriez Pro-Grade magnetic separators come in plate, grate, trap, tube and sight glass versions in a variety of sizes and strengths. The plate magnets are installed in chutes, spouts, ducts or pipes, or suspended over conveyors, to remove tramp iron, while the grate magnets remove ferrous contamination from dry products such as powders or gran-ules. The traps remove ferrous materials from liquid products flowing through 2-, 3- and 4-in. diameter pipelines; they use 316L stainless steel magnetic tubes and various housing designs.Eriez; 888-300-ERIEZ; www.eriez.com

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FINALLY- an intelligent, wireless washdown temperature probe.True mobility. Instant Data Collection. Mobile Database Connectivity.

Sigma CP-90

Up to 300’ clear line of site transmission

For more Information:T: [email protected]

Our Calibrations are NIST Certified and

Traceable

“Plug and Play” with InfinityQS Proficient

Powered by SYNAPSE 2.4 GHz. radio technology

SIGMA EXHIBIT# 5839

Please stop in!

Use any K-type thermocouple

Superior OLED 4 Line display

Multiple send modes

Lithium-ion battery provides up to 48 hours of use

Double gasketed probe junction

Accuracy +/- .5º

2 015 − C H I C A G O

SELF-CONTAINED COMPACTOR Intended for the sanitary handling of general waste, the SP Industries SCM Series mini self-contained compactor system is comprised of an integral compactor, power unit and container. When full, the entire unit is loaded onto a roll-off hoist truck for transport to a disposal site. The system features a maximum packing force of 26,400 lb. SP Industries; 269-793-3232; www.bestcompactors.com

SERVO PUMP FILLERS Hinds-Bock CIP servo pump fillers sanitize themselves; the front cover plates are hinged for sanitation swab testing. The servo con-troller changes over from 1 size container to another without change parts. Fill adjustment is accomplished by calling up a recipe on the HMI panel. The fillers can be used for a range of flowable products including sauces, dressings, jellies, condiments and products with particulates.Hinds-Bock Corporation; 877-292-5715; www.hinds-bock.com


S O U R C E B O O K

T E C H N O L O G Y

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

from one sourceRaw materials, logistics, storage, processing, conveying, preparation, dispensing, mixing, control: we develop extraordinary solutions in all areas. All key components are developed and manufactured in house, and are designed for continuous, effi cient and reliable operation.

Complete knowledge

See us at PACK EXPO Booth

#-S-7816

www.masterbond.com

154 Hobart Street, Hackensack, NJ 07601 USA+1.201.343.8983 • [email protected]

• Meets FDA Section 175.105 specifications for indirect exposure to food

• Chemically resistant

• Thick paste

EP21NDFG • Meets FDA Section 175.105 EP21NDFG

Non-Drip Epoxy for Food Equipment Applications

BELT MEASURING SYSTEM The Cambridge Tug Tester measuring system provides tension read-ings on turn and spiral cage conveyor belts used during the cooling and freezing stages of bakery and food processing; it uploads data and tracks changes on a PC for daily plant monitoring. Approved for operating temperatures from -40°F to 120°F, the system can be used on belt loads up to 1,000 lb. with measurements provided every 2 seconds for up to 20 hours at -10°F. It includes a belt loading mecha-nism, rechargeable lithium ion battery and charger, software discs, pins, adaptors and cables. Cambridge Engineered Solutions; www.cambridge-es.com

S O U R C E B O O K

T E C H N O L O G Y


INNOVATIVE PACKAGING SOLUTIONSPACKAGINGSOLUTIONSINTEGRATEDINTEGRATEDINTEGRATED

INNOVATIVE

INDEPENDENTINDEPENDENTINDEPENDENT

[email protected]

bradmanlake.com

CARTONING n CASE PACKING n DISTRIBUTION SYSTEMS n FEEDING SYSTEMS n FLOW WRAPPING n ROLL WRAPPING

n SHRINK WRAPPING n STORAGE SYSTEMS n ROBOTICS

Bristol & Beccles : England n Rock Hill SC : USA Moscow : Russia n Shanghai : China n Mumbai : India

TECHNOLOGY YOU CAN TRUST

PRODUCT FEEDING SYSTEMS ROLL WRAPPERS CARTONERS

CASE PACKERS SHRINK WRAPPERS ROBOTICS

FLOW W

RAPPER

S

PACKAGINGPACKAGINGSOLUTIONSINTEGRATED

INNOVATIVE

INDEPENDENTINDEPENDENTINDEPENDENT

SEE US AT

:

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WORM GEAR SCREW JACKSNook ActionJac worm gear screw jacks feature 1/4- to 100-ton load-handling capabilities and can be used individually or in multiple arrangements; custom configurations are available. The ball screw jacks use a ball screw and nut made from alloy steel with hardened bearing balls carrying the load between the nut and screw for a roll-ing action that reduces friction. The machine screw jacks incorporate an Acme screw with a 2C thread form and have a 20:1 or greater gear ratio.Nook Industries, Inc.; 800-321-7800;www.nookindustries.com

AC SERVO MOTORSBishop-Wisecarver DMV Series AC industrial servo motors have incremental encoders that can be driven by any servo drive with UVW commutation capabilities. Offered as standalone components, they can be selected and sized for use with linear actuators. Pre-wired with 1m-long cable leads, the motors are IP67 protection rated for harsh environments and UL standard compliant.Bishop-Wisecarver Group; www.bwc.com

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TEMPERATURE CALIBRATION SOFTWARECompatible with Microsoft Windows 7 and 8 operating systems, Fluke MET/TEMP II temperature calibration software version 5.0 is used for testing batches of sensors, calculating characterization of coefficients and generating calibration reports. It automates batch calibrations of platinum resistance thermometers, liquid-in-glass and bimetallic thermometers, thermistors and all types of thermocouple sensors.Fluke Calibration; 877-355-3225; www.flukecal.com

STRAPPING MACHINE Available in Base and Pro versions, the Mosca fully automated SoniXs TR-6 strapping machine can be integrated into any food industry operation. Both versions are constructed with a Standard 6 strap path system. With 2 coils as an option, when the first coil is empty, the machine automatically picks up the second and changes the strap, without interrupting production. Mosca GmbH; www.mosca.com


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MILD-STEEL CONSTRUCTED CONVEYOR The Multi-Conveyor mild-steel constructed conveyor provides gap registration and bent tip detection for tubed products; the tubes fall directly into position due to the pockets designed in the conveyor belt. If a bent tip is detected, a stainless steel box-in-box reject pusher guides the tube into a reject shoot. The tubes are rejected on the fly for continuous line movement. Multi-Conveyor LLC; 800-236-7960; www.multi-conveyor.com

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CASE PALLETIZING SYSTEM Designed for the food and beverage industries, the Dematic AMCAP automated mixed case palletizing system arranges cases on a pallet in a specific sequence. Full pallets of an SKU are de-layered by a robot. The cases are singulated and placed into an automated buffer staging module. Performance optimizing software releases the cases from the buffer in a precise sequence for pallet assembly. A robotic palletizer receives the cases and automatically builds the pallet.Dematic; www.dematic.com

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CIRCULATION HEATERS Capable of heating liquids or gases, CAS PUR-X circulation heat-ers are intended for the food and beverage industries. Available in 2 sizes, the heaters feature a Teflon-coated cast aluminum body and a replaceable PFA fluid tube that withstands temperatures to 500°F. Typical applications include the heating of water, juices, milk or foods; the heating of mixing agents and flavoring liquids; and pro-cesses for cleaning and disinfecting. The heaters are equipped with explosion-proof electrical enclosures for deployment in hazardous environments.Cast Aluminum Solutions; www.castaluminumsolutions.com

SECURITY ROUTERS The Phoenix Contact RS2005 security router has 5 unmanaged Ethernet ports and a 4-port managed switch for multiport security applications in Ethernet networks. The RS4004 model has 4 managed ports and a 5-port unmanaged Ethernet switch with an auto-crossing function. Both versions include a “demilitarized zone” port to secure multiple networks. Phoenix Contact; 800-322-3225; www.phoenixcontact.com

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X-RAY FLUORESCENCE SPECTROMETER Enabling at-line analysis for food producers and manufacturers, the SPECTRO portable SPECTROSCOUT X-ray fluorescence spectrom-eter offers laboratory-quality elemental composition monitoring, quality control testing and audit-traceable results. Offering sensitivity at a range of detection levels, it provides precise analysis from high-percentage concentrations to trace elements. The unit includes an intuitive interface, software that interacts via a standard computer and predefined applications packages. SPECTRO Analytical Instruments; www.spectro.com


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PALLET TRUCKS Able to perform in harsh environments such as coolers, wet rooms and freezers, UniCarriers 5.2hp, AC-powered Platinum RPX walkie/rider pallet trucks come in 6,000- and 8,000-lb. capaci-ties. The fork design features a push-type linkage and tie rods to absorb high-impact shocks, while alloy steel fork slides facilitate pallet entry and exit.UniCarriers Americas Corporation; www.unicarriersamericas.com

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ROTARY LOBE PUMP The NETZSCH all-metal TORNADO T2 rotary lobe pump is engi-neered for the hygienic processing of sensitive food industry prod-ucts. It comes in a variety of sizes delivering quantities of 2,113 to 36,980 gal./hr. Used for intermittent, continuous and metering applications, the self-priming, valve-less, positive displacement pump handles any kind of liquid, including media containing gas, solids or fibrous matter. It features a deflection-resistant shaft material and sealed-for-life, angular contact ball bearings.NETZSCH Pumps & Systems; www.netzsch.com

IML SYSTEM Designed for applications on injection molding machines, the Beck-Flex side-entry automated IML system handles molds with as many as 4 cavities. It can decorate labeled lids and containers up to 220 x 100mm in size; the maximum product height is 170mm. The system is compatible with flat labels, 3- or 5-sided labels, 5-sided labels with closed edges and 360° labels. A servo portal enables job-specific label feed and product placement.Beck Automation AG; +41 (0) 44 751 84 44; www.beck-automation.com


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LASER DISTANCE SENSOR Available with an analog output, the Banner Q4X laser distance sen-sor is used for fill level indication, part positioning, roll diameter, loop control and thickness/height verification; the sensor offers continu-ous measurement and sensing performance, in addition to resolu-tions as small as 0.15mm. It provides analog (V or mA) or distance (mm) readouts from the angled 4-digit display that can be viewed from multiple vantage points. Banner Engineering Corp.; 888-373-6767; www.bannerengineering.com

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CHECKWEIGHERS The fixed-height Thermo Scientific Global VersaWeigh checkweigher is used with prod-ucts up to 22 lb. in weight, while the canti-levered, height-adjustable Global Versa GP model is suitable for products weighing up to 6.6 lb. Designed for companies that pack-age products in pouches, bags, cartons and more, the checkweighers are engineered for wet or dry environments.Thermo Fisher Scientific Inc.; 763-783-2500; www.thermofisher.com

SPOUTED DISPENSINGA flip-top, 1-piece, spouted dispensing unit for flexible pouches, the WestRock FlexFit closure has a “latch-back” design that keeps the cap away from product during dispens-ing; it comes in a range of orifice sizes and shapes. Made of high-density polyethylene, the closure can be used in food applica-tions, such as condiments, flowable powders, sugar and dehydrated beverages. WestRock Company; www.westrock.com

FLAT PANEL DISPLAYSSuited for harsh environments, AbraxSys industrial rack mount LCD flat panel dis-plays have a range of controls and standard spaced holes for 19-in. rack mounting. The front bezel and rear housing are construct-ed of aluminum dipped in zinc chromate and finished with a corrosion-resistant, thermal-set black powder coating. AbraxSys Corporation; 800-883-9050; www.abraxsyscorp.com

SEALS AND REPLACEMENT KITSAGD DURA-SHIELD seals for the dairy and food processing industries are manufactured under CEMA dimensional standards. They can be used in applications such as screw conveyors, bucket elevators, mixers, screw feeders, crushers, ribbon blenders and powder or slurry process-ing. Rebuild kits with step-by-step instructions are available. Colonial Seal Company; www.colonialseal.com

Change is the new normal

The world’s top 100 food & beverage companies


} Claire Rowan, Contributing Editor

perating in today’s uber-global, volatile world is challenging existing corporate str uctures and forcing the food and beverage industry ’s leading players to become ever more adaptable, responsive,

proactive and innovative. Competition remains tight as growth in the developing world continues, although at a slower pace than in the initial boom years . Developed n a t i o n s g r a p p l e with ongoing costs an d l egac y i n f ra-structure pressures.

“ T h e b u s i n e s s env ironment was a g a i n m a r k e d b y great uncertainty in 2014,” Nestlé’s lead-ership team said in a presentat ion to shareholders. “Dis-r uptive socioeco-nomic and political change continued to affect growth in many parts of the world. In the emerging markets, economic volatility wors-ened as growth rates slowed and currencies weakened. In the developed markets, deflationary pressures and soft consumer demand resulted in a continued challenging trading environment.”

During 2014, Nestlé, which again remained firmly in its top spot in the food and beverage industry, integrated its Maghreb, Middle East, North East Africa region, Tur-key and Israel into Zone Europe to form Zone EMENA (Europe, Middle East and North Africa).

“This,” Nestlé says, “balances the different consumer dynamics and opportunities in these geographies. Addi-tionally, it allows a sharper focus in zone Asia, Oceania and Africa— the fast-growing parts of the world where

three-quarters of the global population live—enabling us to dedicate more attention to countries and regions that are highly complex but have huge potential.”

The Coca-Cola Company, which slipped from third to fifth place in 2014, also began reshaping its organization early last year, only to “accelerate the pace and broaden the scope” of this change during the ensuing months.

“Globally, families and individuals spent less on con-sumer goods in 2014, slowing growth in nonalcoholic beverages, which had an impact on our performance,” says Muhtar Kent, CEO of The Coca-Cola Company. “We knew we needed to move faster and execute faster, and we believed we could improve.”

During 2014, the company streamlined and sim-plified its operating model, reducing the size of its group-level organizations around the world, standard-izing its operating approach and key processes across business units and, most notably, forming a single business unit in Western Europe, where it previously had three. The company also put greater emphasis on revenue and profit growth by segmenting activities in each of its core markets.

O

Global volatility in both socioeconomic and political terms, shifting demographics and an explosion in e-commerce created an increasingly challenging backdrop to activities during the past year.

“Globally, families and individuals spent less on consumer goods in 2014, slowing growth in nonalcoholic beverages, which had an impact on our performance,” says Muhtar Kent, CEO of The Coca-Cola Company. “We knew we

needed to move faster and execute faster, and we believed we could improve.”

on consumer goods in 2014, slowing growth in nonalcoholic beverages, which had an impact on our performance,” says Muhtar Kent, CEO of The Coca-Cola Company. “We knew we


“In emerging markets, we’re striving to grow mostly via greater volume to drive awareness and build our brands. In developing markets, we know ideal growth takes a bal-ance of volume and pricing, while in developed markets, we see price/mix as our most powerful growth lever,” Kent explains. “Overall, these steps will allow us to speed decision-making and enhance our local market focus, both of which will help unlock growth. We’ll also have a more nimble organization, one better equipped to outpace the change in our industry.”

Innovation in JapanAt the beginning of this year, the Sapporo Group formulated a completely new management plan in response to the “pro-gression of business operations during 2014 and the current business environment.”

“We recently announced the Sapporo Group’s New Man-agement Framework, which sets its sights on 2016, our 140th anniversary,” says Tsutomu Kamijo, president of Sap-poro Group, who explains that in the past, plans were grounded on the conditions current at the time they were conceived. “In contrast, the New Management Frame-work envisions the company in the year 2016 and out-lines the policies to make the changes required to achieve that vision. We will pursue greater synergies among our businesses by promoting flexible collaboration and cooperation, unconstrained by our current group com-panies or existing organiza-tional boundaries.”

As part of the plan, Sappo-ro will look for further mar-ket penetration of its brand in premium beer markets

such as North America and Southeast Asia. It has already earmarked the US beverage manufacturer Country Pure Foods, which it will acquire with Toyota Tsusho America Inc. through the two com-panies’ US fruit beverage manufacturing joint venture organization, Silver Springs Citrus Inc.

Fellow leading Japanese player, Nissin Foods Holdings, has adopted a strategy of acquisition and innovation to become more compete-tive. For example, last year, it acquired a 49 percent stake in Indonesia’s PT Nissinmas to strengthen its position in instant noodle products, such as Cup Noodles and Top Ramen Baru. Facing limited growth in the domestic market, Japanese food companies are keen to expand in Indonesia as it has the world’s fourth-biggest population and is Southeast Asia’s biggest economy, according to Nis-sin Foods.

In 2014, the company also inaugurated a new research and development center in Tokyo. “We named it ‘the WAVE’ to express our desire to spread a new wave of innovation worldwide by pioneering leading-edge food technologies,” says Koki Ando, CEO of Nissin Foods Holdings. The WAVE houses two research facilities, one of which is the Nissin Global Innovation Center, which provides technical support for innovation.

TOP 100

“I am honored and humbled to be the CEO of the Kraft Heinz Company. Kraft and Heinz are both world-class organizations with storied pasts and together an even brighter future,” says Bernardo Hees.

be the CEO of the Kraft Heinz Company. Kraft and Heinz are both world-class organizations with storied pasts and together an even brighter future,” says Bernardo Hees.

Southeast Asia. It has already earmarked the US beverage manufacturer Country Pure Foods, which it will acquire with Toyota Tsusho America Inc. through the two com-panies’ US fruit beverage manufacturing joint venture organization, Silver Springs Citrus Inc.

The business environment was again marked by great uncertainty in 2014, according to Nestlé. Disruptive socioeconomic and political change continued to affect growth in many parts of the world. In the emerging markets, economic volatility worsened

as growth rates slowed and currencies weakened. In the developed markets, deflationary pressures and soft consumer demand resulted in a continued challenging trading environment. Pictured above are Nestlé CEO Paul Bulcke (left) and Chairman of the Board of Directors Peter Brabeck-Letmathe (right).

marked by great uncertainty in 2014, according to Nestlé. Disruptive socioeconomic and political change continued to affect growth in many parts of the world. In the emerging markets, economic volatility worsened

markets, deflationary pressures and soft consumer demand resulted in a continued challenging trading environment. Pictured above are Nestlé CEO Paul Bulcke (left) and

Peter Brabeck-Letmathe (right).

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Top 100 Food & Beverage Companies

Rank Company Food Sales ($ millions) Year Ending Rank Company Food Sales ($ millions) Year Ending

1 Nestlé 72,245 Dec. 14

2 PepsiCo, Inc. 66,683 Dec. 14

3 JBS 52,580 Dec. 14

4 Anheuser-Busch InBev 47,063 Dec. 14

5 The Coca-Cola Company 45,998 Dec. 14

6 Archer Daniels Midland Company 43,232 Jun. 14

7 Tyson 37,580 Sep. 14

8 Mondelez International 34,244 Dec. 14

9 Cargill 33,700 May 14

10 Mars 33,000 Dec. 14

11 Unilever 29,070 Dec. 14

12 Danone 28,545 Dec. 14

13 Kraft Heinz 28,000 Dec. 14

14 SABMiller 26,177 Mar. 15

15 Heineken 26,000 Dec. 14

16 Lactalis 22,240 Dec. 13

17 Suntory 21,540 Dec. 14

18 Kirin Holdings 18,653 Dec. 14

19 Fonterra 18,565 Jul. 14

20 General Mills Inc. 17,910 May 14

21 ConAgra Foods Inc. 17,703 May 14

22 Asahi Group 17,017 Dec. 14

23 Diageo 15,900 Jun. 14

24 Royal FrieslandCampina 15,320 Dec. 14

25 Kellogg Company 14,580 Dec. 14

26 CHS Inc. 14,500 Aug. 14

27 Grupo Bimbo (Mexico) 14,390 Dec. 14

28 Arla Foods 14,330 Dec. 14

29 Smithfield Foods Inc. 13,221 Apr. 13

30 Brf Brasil Foods 13,185 Dec. 14

31 NH Foods 12,108 Mar. 15

32 Carlsberg 11,730 Dec. 14

33 Ferrero 11,355 Aug. 14

34 Femsa 11,330 Dec. 14

35 Pernod Ricard 11,045 Jun. 14

36 Vion 10,975 Dec. 13

37 Danish Crown 10,550 Sep. 14

38 Meiji Holdings 10,218 Mar. 15

39 Bunge 10,035 Dec. 14

40 Saputo 9,690 Mar. 15

41 Marfrig Group 9,580 Dec. 14

42 Dean Foods Company 9,503 Dec. 14

43 Yili Group 9,390 Dec. 14

44 Hormel Foods Corporation 9,316 Oct. 14

45 Yamazaki Baking 9,220 Dec. 14

46 Sudzucker 9,180 Feb. 15

47 Associated British Foods 9,020 Sep. 14

48 Coca-Cola HBC 8,790 Dec. 14

49 Maruha Nichiro Corporation 8,390 Mar. 15

50 China Mengniu Dairy Company 8,340 Dec. 14

51 Campbell Soup Company 8,268 Jul. 14

52 Coca-Cola Enterprises 8,264 Dec. 14

53 Kerry Group 7,770 Dec. 14

54 Parmalat 7,490 Dec. 14

55 The Hershey Company 7,422 Dec. 14

56 DMK Deutsches Milchkontor 7,365 Dec. 13

57 Sodiaal 7,290 Dec. 14

58 Oetker Group 7,100 Dec. 13

59 Red Bull 6,900 Dec. 14

60 McCain Foods Limited 6,860 Jun. 13

61 Muller Group 6,810 Dec. 13

62 Ajinomoto 6,485 Mar. 15

63 Savencia Fromage & Dairy 6,220 Dec. 14

64 Dr Pepper Snapple Group 6,121 Dec. 14

65 Constellation Brands 6,028 Feb. 15

66 Ingredion Inc. 5,998 Dec. 14

67 The JM Smucker Company 5,963 Apr. 15

68 Morinaga Milk Industry 5,948 Mar. 15

69 Nissui 5,818 Mar. 15

70 Bacardi 5,800 Mar. 14

71 LVMH 5,365 Dec. 14

72 Barry Callebaut 5,300 Aug. 14

73 Land O' Lakes Inc. 5,098 Dec. 14

74 ThaiBev 5,065 Dec. 14

75 Barilla 4,915 Dec. 13

76 Tsingtao Brewery 4,840 Dec. 14

77 Itoham Foods 4,810 Mar. 15

77 tie Maxingvest/Tchibo 4,810 Dec. 13

79 Schreiber Foods 4,800 Dec. 14

80 Sapporo Holdings 4,650 Dec. 14

81 Nisshin Seifun Group 4,507 Mar. 14

82 Dole Food Company, Inc. 4,500 Dec. 14

83 Coca-Cola Amatil 4,495 Dec. 14

84 Nissin Foods Group 4,315 Mar. 15

85 Ito En 4,305 Apr. 15

86 McCormick Corporation 4,243 Nov. 14

87 Agropur Cooperative 4,240 Dec. 14

88 Tate & Lyle 4,175 Mar. 15

89 Molson Coors Brewing Company 4,146 Dec. 14

90 QP Corporation 4,105 Nov. 14

91 J R Simplot 4,000 Aug. 14

92 Brown-Forman 3,946 Dec. 14

93 Coca-Cola West 3,905 Dec. 14

94 E & J Gallo Winery 3,800 Dec. 14

95 Groupe Bel 3,757 Dec. 14

96 Flowers Foods 3,749 Dec. 14

97 DE Master Blenders 1753 3,645 Dec. 14

98 Keurig Green Mountain 3,605 Sep. 14

99 WhiteWave Foods 3,437 Dec. 14

100 Japan Tobacco International 3,425 Dec. 14

Source: Global Food Markets (GFM), Leatherhead Food Research; www.leatherheadfood.com.

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TOP 100

“Until now, it was necessary to confirm and establish pro-duction conditions for trial products through line tests on actual production lines,” says Ando. “The installation of a full-specification, continuous, multi-product, configurable pro-duction line within the research center will enable us to study full-scale production conditions in advance and shorten the time for product launch.

“Winning the race for new products and markets is fierce in the instant noodle industry, and shortening development times is important for successfully competing in the market,” adds Ando. “Our new research center will now assume a cen-tral role in an effort to develop completely new products that fuse Nissin’s various food processing technologies.”

Nissin’s second research facility, the Nissin Global Food Safety Institute, will be responsible for ensuring food safety.

Focus on the AmericasIn the meat world, acquisition and divestiture punctu-ated activities at the top. For instance, JBS, at number three, pounced at the opportunity to purchase the British poultry producer Moy Park from fellow Brazilian meat giant Marfrig just a few months ago. The acquisition gives JBS access to markets in Britain, Scandinav ia and other parts of Europe, where consumption of processed food is r ising. Although most of Moy Park’s sales come from fresh produce, processed meat accounts for 40 percent of its sales.

For Marfrig , which has recently relaunched itself as Marfrig Global Foods,

the sale allows it to focus more intensely on pursu-ing growth opportunities by expanding its Keystone foodservice business in both Asia and the US; increas-ing beef exports from Bra-zil, especially to Asia and the US; and strengthening its capital str ucture and increasing its cash f low. T h e s e m o v e s m e e t t h e requirements of the com-pany’s strategic plan, Focus to W i n , w h i c h c o n c e n -trates on organic growth, margin expansion and cash generation.

According to Marfrig CEO Martin Secco Arias, “The com-mitments we assumed under Focus to Win will continue to guide Marfrig’s day-to-day operations and allow us to focus on the importance of cost management, high productivity and operational efficiency.”

New in at number 99 this year, WhiteWave Foods, the spi-noff from Dean Foods that began operation as a standalone company in 2013, has also been busy forging its growth through acquisition. Last year, via a joint venture established earlier with China Mengniu Dairy, WhiteWave entered an agreement to purchase Yashili Zhengzhou in China. In Octo-ber and closer to home, WhiteWave completed its acquisi-tion of So Delicious Dairy Free, and very recently, it seized the opportunity to extend its plant-based food and beverage offerings through the acquisition of Vega, a leader in plant-based nutrition products—primarily powdered shakes and snack bars containing nutrient-dense, superfood ingredients.

“We highlighted our first full year as a standalone company not only by achieving strong market and financial results, but also by acquiring Earthbound Farm and So Delicious. We

“Winning the race for new products and markets is fierce in the instant noodle industry, and shortening development times is important for successfully competing in the market,” says Koki Ando, CEO Nissin Foods. “Our new research

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Putting the company’s information technology and e-commerce organizations under the sight of a vice chairman will accelerate new solutions and further strengthen PepsiCo’s digital

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also launched our plant-based joint venture in China,” says Gregg Engles, chairman and CEO. “WhiteWave is the fastest-growing food company in America, and our Alpro plant-based foods and beverages are experiencing enviable growth in our core Western European markets. In North America, we hold the top market share in plant-based foods and beverages [with Silk and So Delicious].”

In 2014, W hiteWave introduced Silk cashew milk and relaunched its dairy-free yogurts in the US. Plus, via its joint venture with Mengniu Dairy, it completed the construction of a production facility in Zhengzhou, launching almond and

walnut beverages in China under the Silk ZhiPuMoFang brand in December.

Dairy industry challengesPursuing investment in the complex dairy sector, which i s plag ued by f luctuat ing commodity prices and the challenge of meeting Asia’s insat iable demand for i ts products, Fonterra recently inaugurated its first produc-

tion site in Europe. The site at Heerenveen in the Nether-lands is now one of Fonterra’s three key global production “pools” alongside plants in New Zealand and Australia.

“The commissioning of this new plant further strengthens our ability to deliver high-quality, advanced dairy nutrition that meets the needs of our priority markets and global cus-tomers,” says Theo Spierings, Fonterra’s chief executive. Last year, Spierings oversaw the formation of the global partner-ship between Fonterra and Beingmate that is strategically designed to help meet China’s growing demand for infant formula (from foreign suppliers in particular).

According to Marfrig CEO Martin Secco Arias, “The commitments we assumed under Focus to Win will continue to guide Marfrig’s day-to-day operations, as well the importance of cost management, high

productivity and operational efficiency.”

According to Marfrig CEO Martin Secco Arias, “The commitments we assumed under Focus to Win will continue to guide Marfrig’s day-to-day operations, as well the importance of cost management, high

Dairy industry challengesPursuing investment in the complex dairy sector, which i s plag ued by f luctuat ing commodity prices and the challenge of meeting Asia’s insat iable demand for i ts products, Fonterra recently


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“In 2014, we focused on building volumes and value in our key markets, especially Asia and Latin America,” Spierings con-tinues. “In Asia, we saw 12 percent volume growth, primarily driven by our excellent performance in China. In Latin America, our Soprole business’s focus on new product development and innova-tion contributed to the region’s 3 percent volume growth. But, unfortunately, our New Zealand and Australian business had a challenging year due to much higher input costs.”

Commenting on Fonterra’s revision of its forecast for last year, Chairman John Wilson says, “It reflects an uncertain outlook for the global economic environment and an expecta-tion of continued volatility for dairy prices driven by geopo-litical events and the supply/demand imbalance.”

Tackling the dairy market volatility, Danone plans to sell its Dumex infant milk powder business in China to Yashili International Holdings, giving Danone the cash it needs to

increase its stake in Mengniu Dairy. The move also will allow Danone to exit China’s infant formula sector following a decline in demand for Chinese-made products, due to con-tinuing food scandals such as the June 2015 recall of infant formula powders contaminated with dangerously high levels of nitrate.

Falling consumer confidence in the Chinese market has led to increased investment overseas, particularly in New Zealand, where infant formula products are seen as being of higher quality. The preference for foreign products has led to a changing dynamic for China’s “digi-savvy” consumers.

“We highlighted our first full year as a standalone company not only by achieving strong market and financial results, but also by acquiring Earthbound Farm and So Delicious. We also launched our plant-based joint venture in China,” says Gregg Engles,

chairman and CEO, WhiteWave Foods.

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According to the Institute of Grocery Distribution (IGD), China’s online grocery market is the largest in the world and is set to be five times its current value by 2020.

“Foreign brands are popular with Chinese shoppers who are wary of the safety scares surrounding locally sourced food and drink. Consequently, companies such as Alibaba and Amazon have recently introduced sites dedicated solely to imported goods,” says Joanna Denney-Finch, IGD chief executive. “Many Chinese people also prefer shopping using their smartphones, so retailers are offering mobile-only promotions, which are updated regularly to encourage shoppers to keep visiting their websites for the latest deals.”

Enter the digital ageThis shift to digital is altering the entire operation landscape for food and beverage manufacturers. For example, in its bid to keep up with the changing face of e-commerce, Pepsico has named its executive vice president and chief financial officer, Hugh Johnston, as vice chairman. In this new role, he will oversee the company’s global e-commerce organization, plus its global business and information solutions function.

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Mondelēz International is tapping into digital trends and has renewed its global strategic partnership with Facebook to deliver creative video content and drive impulse snack purchasing online. Nestlé is increasing its presence in Sili-con Valley, forging partnerships with startups and leading technology companies to build on its digital innovation and relationships with consumers by providing them with inno-vative online experiences and services. But, such activity is just the tip of the iceberg in this changing digital world.

“It took radio 38 years to attract 50 million listeners, but Facebook attracted 6 million users in its first year, and that number multiplied 100 times over the next five years. Chi-na’s mobile text- and voice-messaging service WeChat has 300 million users, more than the entire adult population of the US,” says the McKinsey Global Institute in its new book, “No Ordinary Disruption: The Four Global Forces Break-ing All the Trends.” Accelerated adoption invites accelerated innovation. But, despite how fast innovation has multiplied and spread in recent years, it is poised to change and grow at an exponential speed.

According to the McKinsey Global Institute, “Twenty years ago, less than 3 percent of the world’s population had a mobile phone; now two-thirds of the world’s population has one, and one-third of all humans are able to communicate on the Internet. Entrepreneurs and startups now frequently

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The institute’s book makes for stimulating, if not alarming, reading, and it is clear only the flexible and fit companies will prevail in such a changing environment. But, that will require adaptability and resilience.

“Although we are operating in a challenging and turbulent economic environment, we see these as fascinating times, full of opportunities,” says Nestlé.

No comment on the turbu-lent times in the industry and activities at the top would be complete this year without mentioning the landslide deal completed in July between Kraft Foods and Heinz. The two iconic names merged to create the Kraft Heinz Com-pany, which, under the leader-ship of new CEO Bernardo Hees, took the 13th position among the global top 100.

“I am honored and humbled to be the CEO of the Kraft Heinz Company. Kraft and Heinz are both world-class orga-nizations with storied pasts and together an even brighter future,” says Hees. He adds that the company’s immediate focus is on integrating the two businesses and establishing a new organizational structure, while delivering on its financial objectives for 2015.

The developments of 2014 may just be the beginning. Global mergers, acquisitions and restructuring are likely to continue for the foreseeable future as the operating landscape for food and beverage manufacturers remains in flux. ❖

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Whether your plant is located in a drought-stricken area or where water is plentiful, building a wastewater treatment center on site may be cost effective for several reasons.

Wayne Labs, Senior Technical Editor

ith the Sun Belt states experienc-ing serious droughts and the cost of processing wastewater escalat-ing in many municipalities, con-serving and reusing water at food

and beverage processing facilities just makes plain business sense. There are two ways to cut expenses on water: conserve it and pretreat wastewater before sending it off to publicly owned treatment works (POTWs) since many of them charge extra for untreated sewage or may not take it at all.

You can, of course, conserve water throughout your plant by preventing wasteful amounts from going down the drain, because the more you process

it (e.g., create steam or hot water, pump or filter it, etc.), the more valuable a loss it is.1 Many processors are already up to speed on pretreatment systems and have found these systems can evolve into a larger-scale processing facility where wastewater can not only be pretreated, it can be recycled as clean or even potable water for other uses within the facility. Processed wastewater also can produce energy.

Although some food and beverage processors have discovered onsite pretreatment or further polishing (i.e., refining) of wastewater for use within the facility ultimately saves money, local municipali-ties are just catching up with the concept of waste-water reuse, and this is mostly in the states affected

W

Weighing all the options in wastewater treatment

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}

} The ADI-BVF reactor (a low-rate anaerobic process) at the Shearer’s Foods Massillon, OH site handles degradable TSS and reduces BOD from 3,000 to 5,000mg/l to an effluent level less than 300mg/l. The plant processes corn and potatoes for snack foods, including potato chips, tortillas, rice crisps and cheese curls/puffs. Source:

ADI Systems Inc.


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by ongoing drought. Only 6.4 percent of municipal wastewater flows in the US are reused for industrial, irrigation or munici-pal purposes, according to the Bluefield Research report, “US Municipal Wastewater & Reuse: Market Trends, Opportuni-ties & Forecasts, 2015-2025.”2

What’s your raison d’être for waste-water treatment?Though processors often place different priorities on setting up an onsite wastewater pretreatment—or complete treatment—system, altruism is usu-ally not the first reason. CDM Smith Associate Al Goodman lists four typical reasons for setting up a wastewater treatment system:

• Compliance with discharge requirements. High BOD (biological oxygen demand) or TSS (total suspended solids) in wastewater generally needs treatment to comply with city or stream dis-

charge requirements.• Reduction of sewer surcharges for excessively strong

wastewater. • Recovery of useful products for resale, e.g., onsite solids

used as animal feed or compost production.

The following factors (where applicable) should be considered when determining the ROI for onsite wastewater treatment:

• Planning and design cost• Environmental compliance (e.g., reporting)• Permitting costs• Capital cost for the wastewater treatment plant• Operating costs, including: -- Electrical power required to operate the treatment plant -- Maintenance costs, including allowance to replace

large equipment, membranes, etc. at the end of their serviceable lifetime

-- Manpower to operate the treatment plant -- Hauling dewatered sludge or out-of-spec product not suit-

able to be discharged to the wastewater treatment plant -- Chemicals for operating the wastewater treatment

plant (nutrients, polymer, cleaning chemicals, etc.)• Savings or elimination of POTW surcharges• Reduction in volume of waste product to haul off site• Value of water that can be reused• Value of biogas energy that can be recovered

• Value of granular anaerobic sludge generated in a high-rate anaerobic digester

• Incentive programs for instituting onsite wastewater treat-ment, green energy production, water recovery, etc.

Additionally, the following factors, which may not be easy to quantify in an ROI analysis, should be considered when weighing the choice to conduct onsite wastewater treatment:

• Threat of lost production days for severe discharge violations• Installing water reuse technology serves as a form of insur-

ance against a future restriction of water supply. Water reuse serves as a form of risk management by facilitating internal management of the plant’s water supply needs.

• Positive publicity from instituting green energy production or water recovery systems, showing the production plant’s environmental responsibility

• Improved relationships with neighbors, suppliers and vendors.

Source: ADI Systems.

ROI wastewater treatment system development cost factors

An ADI-BVF low-rate anaerobic reactor helps the Bellisio Foods Jackson, OH facility meet the city’s POTW discharge limits for COD and TSS. The system includes a 250,000-gallon EQ tank, 5.25 MG above-ground anaerobic BVF reactor, 300,000-gallon once-through aeration tank and a standby power generation unit. Source: ADI Systems.

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• Recovery of water for reuse. This involves more extensive wastewater treatment, but is becoming a significant driver to industries in water-stressed areas.

While these reasons are certainly practical, it may be harder to put a value on “social pressures,” as Lisa Schilling, marketing manager at Veolia Water Technologies notes. “With the social ‘right to oper-ate’ a plant in a community, manufacturers are doing everything they can to retain or develop a positive local reputation to protect their brand. Installa-tion and operation of effective onsite wastewater treatment is one way a manufacturer can ensure it will be viewed positively by the local community it operates in.”

Having the right kind of waste stream also allows processors to recover energy, according to Scott Christian, ADI Systems vice president, business development. “Food and beverage processors can generate high-strength wastewater that is amenable to anaerobic digestion. Employing anaerobic diges-

tion wastewater treatment onsite not only drasti-cally reduces the COD [chemical oxygen demand] and TSS concentrations of the wastewater, it also generates biogas that can be used onsite in boilers and/or dryers, or to generate electrical power.”

Specific compliance issues besides BOD and TSS include a processor’s inability to meet wastewater limits for pH; fats, oil and grease (FOG); and excess nutrients such as nitrogen and phosphorous, which have been problematic in many areas with ground water contamination, says Stephen Schulte, manager, environmental, health & safety, Hixson Architecture & Engineering. Schulte also points out that in some areas, there just isn’t a POTW to handle processors’ wastewater, so having one onsite is a necessity.

Dry timesNot every food and beverage plant has all the water it needs, and many states are feeling the pinch of decreasing water supplies as the climate changes.

Anticipating increases to production, the Wayne Farms Pend-ergrass, GA facility wanted to update its existing SBR, lagoons and land application system (LAS) wastewater treatment system. The single-tank SBR and LAS had reached capacity and couldn’t handle significant additional flow. Wayne Farms applied for and was issued a National Pollutant Discharge Elimination System (NPDES) permit for direct discharge to Allen Creek, a tributary of the Middle Oconee River watershed.

To meet the NPDES limits, Wayne Farms had to upgrade the existing wastewater treatment plant to provide higher removal efficiency. Considering the potential water shortage and drought issues within Georgia, the processor wanted to recycle and reuse the treated effluent in non-food contact areas within the plant.

The facility’s existing activated sludge (AS) system used a 1.6 million-gallon SBR and aerated lagoon. Effluent from the production facility was screened and had limited equalization (EQ). From the EQ, the wastewater flowed to a DAF unit, then an aerated lagoon, the SBR and a series of lagoons for further treatment and storage. Treated effluent flowed through the lagoons and was discharged through the LAS. Waste-activated sludge (WAS) was stored in the sludge lagoon.

As part of the new system design, the processor instituted a multiple-polymer system for the existing DAF. The table shows the influent design parameters following the DAF upgrade.

To meet the three main objectives for the wastewater treat-ment system upgrade, Complete Water Services LLC recom-mended an MBR system with de-nitrification, phosphorus

removal and ultraviolet (UV) sanitation. Since MBRs don’t rely on conventional settling and clarification, the concentration of biomass can be increased, therefore, decreasing the overall size of the system while increasing the amount of loading the system can handle. Ultra-filters separate the mixed liquor suspended solids (MLSS), providing a high-quality effluent as permeate.

With the MBR, Wayne Farms’ existing SBR tank was con-verted to a bioreactor. The existing towers are sufficient to maintain the biomass. The wastewater is intercepted after the DAF, keeping the existing screen, limited EQ and DAF in ser-vice. De-nitrification and phosphorus removal add to the recy-clability of the treated wastewater, which meets and exceeds USDA FSIS requirements for reuse in poultry plants.

Influent design parameters following the DAF

Parameter Influent Effluent limitFlow (MGD) 0.8 —

BOD (mg/l) 450 <16

TSS (mg/l) 100 <10

NH3 (mg/l) 22.1 <4

Total nitrogen (mg/l) 100 <103

P (mg/l) 24.3 <1.2

Fecal coliforms (counts/100ml) TNTC <200

Source: Complete Water Services LLC.

Wayne Farms upgrades existing system to MBR

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Aerobic systems:+ Can achieve very low levels of BOD, NH3 and TN+ Simultaneous N and P removals possible+ Minimal odor when properly maintained+ High-rate options allow for very small footprints+ Dissolved oxygen in effluent reduces immediate O2 demand on receiving

waters+ Less susceptible to load variations/upsets; quick recovery+ Best for low-concentration effluents+ Best option for colder climates/wastewaters+ Low to medium capital cost+ Good for all sizes of plants+ Discharges from aerobic systems are often suitable for beneficial reuses+ Depending upon the type of aerobic treatment technology, operations can

range from very simple to relatively complicated.

- Higher energy cost (compared to anaerobic treatment)- Higher sludge production (compared to anaerobic treatment)- May require nutrient supplementation- Maintenance costs associated with blowers/mixers, aeration systems- Require continuous operations; long shutdowns not suggested.

Anaerobic systems:+ Ideal for heavily loaded systems+ Produce biogas+ Very low sludge production+ Low operating costs+ Minimal nutrients required+ Seasonal operations possible+ Generally low maintenance costs.

- May need to be constantly fed sodium bicarbonate to keep them basic for methane formers

- Highly susceptible to toxic events- Medium to high operating cost- Not ideal (economically) for smaller plants- May need to heat system—an issue in colder climates- No significant N or P removal- Low effluent values achieved only with aerobic post-treatment- May require Class I, Div. 1 buildings for ancillary systems/equipment/buildings- Higher capital costs (depending upon system/design)- Effluent needs additional treatment (aerobic) prior to any potential reuse.

Source: World Water Works.

Key pluses/minuses of aerobic/anaerobic systems

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States with POTWs that have been active in setting up water reuse systems include California, Florida, Texas, Arizona, Colorado and Nevada, according to the Bluefield study.

“In a drought-stricken area, the cost of water can be a significant operational expense or limitation,” observes Jeff Cumin, GE Water and Process Technologies senior product manager. “ Wastewater reuse provides an opportunity to avoid local limits of water consumption and maintain or increase production without exposure to increasing freshwater costs.”

But, it’s not just availability or local limits on water use that cause operational problems for processors. “Drought-stricken areas are being regulated more heav-ily than wet areas,” says CDM Smith’s Goodman. “These

} In an MBR, the membrane can be placed next to the aeration basin (external or separate system, as shown in the top image) or in the basin (internal or submerged, as shown at the bottom image). External systems involve continuous crossflow circulation along the membranes. Both tubular and flat plate membranes are used to achieve this action. An internal system involves the effluent being extracted from the active sludge through the membrane by a permeate pump pulling water from the biomass in the aeration tank. This normally involves the use of hollow fibers or flat plate membranes. Source: CDM Smith.


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new regulations protect the pressures put on groundwater use and include parameters for total dissolved solids [TDS], nitrogen and phosphorus. Hence, more advanced wastewater treatment processes for biological nutrient removal [BNR] and membranes such as reverse osmosis [RO] for TDS removal are necessary.”

In drought-stricken areas, wastewater is valued as a potential water supply source. Additional treatment technologies such

as filtration, membrane filtration, ultraviolet disinfec-tion, carbon filtration and/or chlorination may be employed to reclaim all or a portion of the wastewater flow, says Schulte. Then, this reclaimed water can be used for evap-condenser makeup, boiler makeup, flume water and “gray” water for toilets, landscape drip irrigation and cooling water.

A wastewater treatment plant can process water for reuse to industrial standards, and its output stream can be upwards of 40 percent or more, according to Darren Gurney, senior process & business development, applica-

tions technology & innovation water treatment, Linde Gases. A system can provide tertiary treatment and even produce potable water by applying further refinement techniques such as ultra-filter (UF) membranes, RO and ozone/UV treatment. “Some plants may invest in techniques to get ‘zero discharge,’ where they recover effluent water from RO, sludge drying and dewatering. This is practiced in some Persian Gulf States where water is very expensive,” adds Gurney.

Alliance Dairies installed a DVO Two-Stage Mixed Plug Flow anaerobic digester, which protects community water and environmental quality by preventing runoff, odor and greenhouse gas emissions in addition to powering a 1,000kW on-site generator. Source: DVO Inc.

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In some cases, water turnaround can be greater than 40 per-cent. For instance, utilizing a membrane bioreactor (MBR) sys-tem with Mitsubishi Sterapore hollow fiber membrane units, Branston, a potato product producer in Somerset, UK, has realized a 52 percent reduction in mains water usage. This was accomplished by recycling process water through the system, which includes extremely tight control of its 25 closed loops and 50 analog measuring points, according to Heiko Gramsch, Branston development project manager.

Aerobic digester systemsAerobic wastewater treatment is a process where a mixed popula-tion of bacteria uses oxygen to degrade organic matter—generally quantified as BOD—and other pollutants, says ADI’s Christian. “To facilitate the biochemical reactions, the biomass [activated sludge] requires oxygen, nutrients [e.g., nitrogen, phosphorus] and the adequate environmental conditions [pH, temperature, etc.]. The digestion of the wastewater organic material by the activated sludge primarily generates carbon dioxide [CO2] plus additional biological cells.” While the CO2 escapes into the atmosphere, the biological cells are wasted from the system at the rate they’re generated to maintain a stable concentration of biomass within the activated sludge system, adds Christian.

“There are several types of aerobic configurations, with the most common being activated sludge, sequencing batch

reactors, MBRs, trickling filters [bio-towers] and moving bed biofilm reactors,” explains Rick Molongoski, CDM Smith Industrial Services Group, food & beverage division vice presi-dent. The effluent from an aerobic treatment can vary, based on the influent and type of treatment, but can generally produce an effluent with BOD, COD and TSS concentrations less than 30mg/l (≈30 ppm). “While this water is suitable for discharge to a public sewer or for stream or land application, it would need additional treatment to be reused,” adds Molongoski.

“Modifications to conventional activated sludge systems, such as MBRs that rely on physical membranes for solids reten-tion as opposed to gravity clarification, can further improve final effluent quality [free of suspended solids and containing BOD concentrations less than 3mg/l],” says Christian.

“With subsequent unit operations after the aerobic treat-ment, the wastewater can be cleaned sufficiently to allow direct discharge to the environment,” says Bill Guarini, Kusters Water industrial sales manager, food and beverage. Typical post-aerobic operations include dissolved air flotation (DAF), clarification, screening and filtration.

By combining aerobic technology with membrane filtration or MBR, solids- and organics-free effluent can be produced, which can be reused for non-food contact applications or fur-ther polished by RO treatment, offers Jeff Peeters, GE senior product manager.

89www.foodengineeringmag.com | Food Engineering | August 2015

Effluent from activated sludge systems is known as second-ary effluent, says Christian. It is suitable for reuse in grey-water industrial applications such as makeup water for cooling tow-ers or wash water for tanks and equipment. “However, tertiary treatment [such as nano-filtration and disinfection] is typi-cally required to further polish the secondary effluent to meet potable water standards,” continues Christian.

“There is no usable byproduct from an aerobic system,” says Ariel Lechter, president and CEO, Clean Water Technology, Inc. “The drawbacks are that [it] is more expensive to oper-ate and generates a lot of sludge compared to an anaerobic system.” However, the aerobic system can be designed to make the effluent stream as clean as necessary, according to Lechter.

While aerobic treatment is less susceptible to upset or toxicity compared to anaerobic treatment, large pollutant load swings can upset the balance of the overall system, says Hixson’s Schulte. In addition, aerobic treatment requires high energy use for aeration, produces a high biosolids-to-sludge yield and does not remove TDSs, he adds.

So why not combine an aerobic system with an anaerobic system to handle really large applications? After all, nearly all food and beverage plants generate wastewater that is amenable to aerobic treatment. “However, for some of these plants, the operating costs associated with mixing and aeration, sludge dewatering and disposal, and chemical addition [nutrients,

polymer, etc.] can prove to be very high, particularly for those that generate a high-strength wastewater stream and/or a large organic load,” says ADI’s Christian.

In some cases, the wastewater organic load generated by a single food or beverage plant can be comparable to that of a small town or city. When evaluating onsite wastewater treat-ment at a food or beverage plant, anaerobic pretreatment followed by aerobic polishing often provides a more attractive ROI than a system consisting solely of aerobic pretreatment.

Anaerobic systems produce energy“Anaerobic digestion is a complex biochemical reaction car-ried out in a number of steps by several types of microorgan-isms that require little or no oxygen to live,” states Greg Parks, World Water Works VP of technology. During this process, a combined gas product composed mainly of methane [CH4] and CO2, also referred to as biogas, is produced. The amount of gas produced varies depending on the amount of organic waste fed to the digester; temperature influences the rate of decomposition and gas production, adds Parks.

“Anaerobic treatment produces biogas, which is typically 65 to 75 percent methane and can be used as a renewable energy source,” says CDM Smith’s Molongoski. A reliable and fairly consistent loading to the anaerobic treatment process provides a more dependable supply of CH4 biogas. However, the bio-


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gas will generally require some pretreatment to remove water vapor, sulfides and perhaps siloxanes prior to reuse, according to Molongoski.

Since an anaerobic system needs a constant supply of “rich” input, it can be a good option for a dairy operation. For exam-ple, the DVO Inc. two-stage mixed plug flow anaerobic digester installed at Alliance Dairies (Trenton, FL) delivers enough biogas to run a 1,000kW generator, supplying more than 70 percent of the dairy’s electricity. The digester also protects the community and the quality of its water by reducing nutrient runoff, odors and greenhouse gas emissions, according to Steve Dvorak, DVO president.

Anaerobic treatment is generally not as effective at remov-ing TSS, says Molongoski. “It will not reduce nutrients. Plus, it requires higher organic loading than aerobic [i.e., BOD>2,000mg/l] to be cost effective, produces an effluent BOD typically in the 400 to 500mg/l range and may require heating of the reactor if wastewater temperature is low.” On the other hand, anaerobic systems require no oxygen, so energy costs are lower than with aerobic treatment. Dis-posal and dewatering costs also are significantly reduced as a result of low sludge production. Consequently, anaerobic treatment is typically the first step in reducing high-strength wastewaters.

Anaerobic treatment is well suited to the food and beverage industry. “It can be used to treat solids and high-strength bio-degradable organic wastes, such as sugary wastes and fats, and waste produced in sugar beet, dairy or meat processing,” says AT&I Water Treatment’s Gurney. Disadvantages include an effluent that needs further polishing, potential odor problems and the risk of the sensitivity in the process itself. For instance, to maintain a medium- to high-operating pH, the process needs a continuous supply of influent substrate.

“An anaerobic treatment system is typically energy positive,” says Mike Theodoulou, GE senior product manager. “In other words, the system generates more energy than it consumes. As [biogas] is a byproduct of the treatment of organic waste, [an anaerobic system] also reduces or eliminates disposal costs of organic wastes.”

MBR: A good polishing stepIf a processor already has an aerobic or anaerobic—or com-bined—system, but needs further polishing, an MBR can be added. “An MBR is the combination of a membrane process like microfiltration or ultrafiltration with a suspended growth bioreactor. MBRs are now widely used for municipal and industrial wastewater treatment with plant sizes up to 80,000 population equivalent [i.e., 48 million liters per day],” explains

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Ola Wesstrom, Endress+Hauser senior industry manager, food & beverage. “An MBR separates clean water from the activated sludge using membranes that act as a filter.”

Fresh Del Monte Produce Inc. is one processor that uses an MBR to treat pro-cess wastewater. Installed at the company’s

new plant in Oshawa, ON, the ALTECH HydroKleen system treats 40,000 gallons of wastewater per day for BOD, suspended solids, pH and phosphorus to levels below city sewer surcharge limits.

“An MBR system works by combin-ing aerobic treatment with ultrafilters to remove the bacteria and other sus-

pended solids,” says Jim Lewis, president, Complete Water Systems, LLC. This pro-cess produces a very high-quality efflu-ent and can offer many other benefits including reuse-quality water, smaller footprints and reduced chemical usage. An aerobic MBR doesn’t produce energy byproducts, but it does require periodic cleaning of the membranes. (Although not common, there are also some anaero-bic MBRs.) The MBR’s biological system must be maintained like any other aero-bic system.

“Among the three major types of sys-tems, membrane bioreactors have the highest rates of BOD, suspended solids and phosphorus removal,” says Hixson’s Schulte. These membranes create a positive barrier at the end of the treatment pro-cess. In addition, they can pretreat process water for reuse in the plant or for irrigation, require a smaller footprint versus conven-tional aerobic systems and create a lower biosolids-to-sludge yield than conventional aerobic systems. However, membranes are generally more expensive than conven-tional aerobic systems and are much more complex because of the pumps and controls required to operate them. More aeration is also needed than with conventional sys-tems, according to Schulte.

“Aerobic MBR is becoming more com-mon in the industrial wastewater market,” observes ADI’s Christian, although it does have some limitations with influent FOG. Aerobic MBR systems produce very high-quality effluent (nondetect-able BOD and TSS), and extremely low levels of nitrogen (<4mg/l total nitro-gen [TN]) and phosphorus (<0.05mg/l total phosphorus [TP]) are achievable. Aerobic MBR effluent alone can be used for water reuse in some applications and provides ideal feed water quality to RO systems for tertiary treatment, according to Christian.

A number of MBR plants in the US currently treat raw wastewater or anaero-bically pretreated effluent. These include beverage (juice and sports drink), dairy processing (yogurt), potato processing, breweries, snack foods and sauce process-ing facilities, adds Christian.

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Anaerobic or AnMBR technology is ideal for treating high-strength wastewater with high concentrations of TSS and FOG that conventional anaerobic systems don’t handle well. It also produces a very high-quality anaerobic effluent, free of TSS and low in COD/BOD. (In some cases, effluent BOD has been <25mg/l from an

AnMBR). In addition, AnMBR generates biogas and maximizes the amount of its production compared to other anaerobic technologies, says Christian. Like aero-bic system membranes, AnMBR systems require membrane cleaning.

AnMBR systems are now operating at a variety of food and beverage processing

sites for salad dressing/barbecue sauce production, confectioneries, breakfast foods and food waste-to-energy applica-tions. AnMBR technology can be used to upgrade existing anaerobic systems that need additional treatment capacity and/or require better effluent quality. Anaero-bic systems can be retrofitted to AnMBR systems by adding membrane filtration and control systems, says Christian.

BNR protects the environmentIn some wastewater effluents, nitro-gen and phosphorus may be inherent. “Depending on the required use or dis-position of the treated effluent, the inher-ent nutrients may need to be removed to meet discharge requirements, so the receiving municipal treatment facilities or watersheds are not overloaded,” says GE’s Theodoulou. BNR is an aerobic process that is commonly coupled with MBR treatment.

“BNR systems are used for nitrogen and phosphorus removal before dis-charge,” says Veoila’s Schilling. Aero-bic BNR systems convert nitrogen compounds and ammonia to nitrates (known as nitrification), followed by a denitrification process that converts the nitrates to nitrogen gas, which is given off to the atmosphere. The phos-phates in the wastewater are typically removed through precipitation and set-tling and/or filtration and remain in the sludge produced by the process—along with any minute amounts of nitrogen compounds that may not have been completely converted to nitrogen gas, according to Schilling. Sludge contain-ing phosphates may have economic value as enriched bio-solids for fertilizer.

Using BNR combined with the mem-branes in an MBR can make effluent as clean as needed. Additional biomass can be processed by adding more oxy-gen to the system, adds Theodoulou. This can make the solids in the effluent negligible and reduce total nitrogen to under 10mg/l. Phosphorus concentra-tions are dependent on how much chemi-cal is added, but if needed, can be below 1mg/l, estimates Theodoulou.

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“A conventional activated sludge sys-tem can be upgraded to a BNR pro-cess by adding the appropriate tanks and recycle arrangement,” says ADI’s Christian. However, some activated sludge technologies have an inherent ability to achieve BNR. For example, in a sequencing batch reactor (SBR), a

series of process events (fill, mix, aerate, settle, decant or a combination of multi-ple events) occur in a single vessel. The sequence and duration of event times can be arranged so that BNR is achieved with SBR technology, eliminating the need to have multiple tanks dedicated for single-process reactions. Further-

more, SBR technology provides a higher level of process control, as the sequence and duration of events can be changed by the operator on the fly to quickly respond to process requirements.

Incorporating MBR technology into an activated sludge system capable of achieving BNR results in complete con-trol of solids retention time and elimi-nates problems with poor sludge settling, adds Christian. Conventional BNR systems may experience problems with sludge settling, causing biomass wash-out, which can result in process upsets while the biomass recovers, particularly a slow-growing nitrifying population. However, membranes provide complete retention of suspended solids, eliminat-ing the problems associated with sludge settling. Additionally, membrane barriers provide an effective means of prevent-ing the chemical phosphorus precipitate from being discharged into the effluent.

Have it both ways: Clean water and a good ROIMany processors must implement an onsite wastewater treatment system to keep costs under control, reuse water, meet regulatory requirements and/or keep up a good public image. But, can an ROI be expected soon after implementation?

“Each wastewater stream has to be considered separately,” says Veolia’s Schil-ling. Some streams require little or no treatment, so they may be the first can-didates for reuse. Water reduction can be achieved by charting the process for water usage and minimizing excessive use before employing water treatment methods. Keep in mind that most water recycling applications require a combina-tion of treatment approaches.

AT&I’s Gurney has seen MBR applied to brewery, malting, salad, vegetable, dairy and other food operations. Some of them recycle wastewater back to the pro-cess. “The number of plants is not huge, but there is an increasing trend in water reuse being driven by the ‘turnaround cost’ of water.”

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a system. “We have found four operat-ing cost factors that are typically under-estimated when ROIs are performed: labor, chemicals, maintenance and dis-posal,” says Hixson’s Schulte. The hir-ing and licensing of operators can be another significant factor. Licensed operators are typically certified by the

state in which they work. There are several classes of operators, with each certified for a certain level of treatment type and complexity. If the wastewater treatment system discharges directly to surface water, an onsite licensed opera-tor will be required by the state. If the wastewater treatment system discharg-

es into a sewer system, an onsite licensed operator may or may not be required by the state or the local sewer district, explains Schulte.

The potential costs of power, restric-tions on manufacturing capacity, steam and external funding also should be considered. Speaking of external fund-ing, it doesn’t hurt to check in with local, state and federal authorities to see what money may be available to aid in the implementation of a wastewater treat-ment system. Most A&E/C firms and wastewater treatment equipment suppli-ers can help with this determination. For a more detailed checklist of factors to be considered in determining the ROI of a system, see box, “ROI wastewater treat-ment system development cost factors,” on page 78. ❖

References:1 “Water Recovery and Reuse: Guidelines for Safe Application of

Water Conservation Methods in Beverage Production and Food

Processing,” ILSI Research Foundation, Washington, DC, 2013,

www.ilsi.org.2 “ US Wastewater Market to Total $11.0 Billion Through 2025,”

Bluefield Research, July 2015, www.bluefieldresearch.com.

For more information:Al Goodman, CDM Smith, 502-339-0988,

[email protected], www.cdmsmith.com

Lisa Schilling, Veolia Water Technologies, 815-609-2000,

[email protected], www.veolia.com

Scott Christian, ADI Systems Inc., 506-452-7307,

[email protected], www.adisystemsinc.com

Stephen Schulte, Hixson A&E, 513-241-1230,

[email protected], www.hixson-inc.com

Jeff Cumin, GE Water & Process Technologies, 215-355-3300,

[email protected], www.gewater.com

Darren Gurney, AT&I Water Treatment, Linde Gases, +44

01483 579 857, [email protected],

www.lindewatertreatment.com

Bill Guarini, Kusters Water, 864-576-0660,

[email protected], www.kusterszima.com

Rick Molongoski, CDM Smith, 518-782-4500,

[email protected], www.cdmsmith.com

Ariel Lechter, Clean Water Technology Inc., 310-380-4648,

www.cleanwatertech.com

Jeff Peeters, GE Water & Process Technologies, 215-355-3300,

[email protected], www.gewater.com

Greg Parks, World Water Works, 405-943-9000,

[email protected],

www.worldwaterworks.com

Mike Theodoulou, GE Water & Process Technologies,

215-355-3300, [email protected],

www.gewater.com

Ola Wesstrom, Endress+Hauser, 888-363-7377, ola.

[email protected], www.us.endress.com

Jim Lewis, Complete Water Services, LLC, 678-355-9270,

[email protected]

Steve Dvorak, DVO Inc., 920-849-9797,

[email protected], www.dvoinc.net

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dumpster topped off with the day’s malformed products and/or damaged packages. What went wrong, and how do you get a handle on it?

There are many places in a food plant where yield can be improved and, most likely, quality too. Some are more obvious than others. Sometimes, a multitude of factors comes together and stacks up against a day’s production. Issues may be found, for example, in controlling the ingredients being combined into the recipe, filling and packaging—not to mention controlling temperatures in critical

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director, food and beverage strategy. “Directing the steps and activities, monitoring for problems, detecting leading indicators or an actual event and notif ying and orchestrating a response can become a competitive advantage to those who invest in a sense-and-respond solution.”

According to Ron Pozarski, senior marketing manager for Rosemount Flow Products, Emerson Process Management, process optimization and maintaining an optimized opera-tion over the life of the process can significantly improve and maintain yield, increase uptime and reduce energy usage. But processors often f ind themselves tr y ing to reduce downtime while coping with reduced effective capacity due to both internal

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Kangaroo Brands Inc. is a fast-growing maker of ready-to-serve pita bread and sandwiches. To keep up with demand, the pro-cessor realized investing in an end-of-line automated carton-ing system with the ability for quick changes was an absolute necessity. Floor space, however, was limited. It chose an Ultra Packaging, Inc. compact, servo-driven Veronica VHL vertical cartoner, powered by a complete drives/control system from Bosch Rexroth Corporation.

The seven-axis cartoner enables 10 to 15 minute changeovers and uses servo technology that reduces linkages and machine components by 60 percent compared to prior models. Cabling costs were down by 40 percent, and field wiring dropped by 40 percent due to industrial networking (such as Sercos III, PROFI-BUS, PROFINET and EtherNet/IP).

Since the installation, Kangaroo monthly production has grown exponentially from the original throughput of 250,000 pieces per month. Now, the processor produces seven different types of frozen RTE sandwiches made with pita bread baked on the premises and packaged in multiple carton sizes (four-, six-, 12- and 14-count) for large retailers and big-box stores.

According to Kangaroo Plant Manager Justin Rice, “During an average week, we may perform 16 to 18 carton changeovers for various customers. Typically, they only take 10 to 15 minutes.” Plus, with a Rexroth VCP 35 HMI, operators have complete

machine control; IndraWorks software provides the tools for project planning, programming and diagnostics.

The new system has provided a 10-fold increase in production compared to the older manual methods, fits the existing floor space and has saved $130,000 per year in workforce costs. In addition, the cartoner saves about $20,000 per year in cartoning supplies.

Improving yield big time

A simple solution for improving machine control and yield, a small PLC/HMI combination (IDEC FT1A SmartAXIS Touch) controller can work with a bag filling or other application to provide automated cycle and process control, in addition to providing data output to other hardware and data collections systems. Source: IDEC.

Bosch Rexroth automation provides the backbone for the Ultra Packaging Veronica vertical cartoner, boosting yield for Kangaroo Brands by a factor of 10. Source: Bosch Rexroth.

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industry commercial manager. “A less common focus is refining the limits of a process’s con-straints, which allows manufacturers to know how much material should go into each product and create less waste with every production run.”

However, many food manufacturers’ systems may be unable to maintain process control with more refined constraints, adds Rao. “This lost opportunity to improve yield is why an advanced process control system is important for manufac-turers that need to increase efficiency over a large variety of product lines to remain competitive.”

It starts with the ingredients“The most common raw material loss areas in the food and beverage industry are related to net-weight fill and changeovers,” observes Katie Moore, GE Intelligent Platforms global industry manager. “Consequently, many manufacturers focus on these first.” Moore, who once served as a food plant manager, has seen these issues firsthand. The limitations around net-weight fill may be due to the precision (or lack thereof ) of the equipment processing the products. For example, when a cer-tain large snack food manufacturer employed tools to check fill, daily waste went down from 2,000 to 200 lbs., film was saved, and net-weight fill opti-mization resulted in six to seven figures of dollar savings per plant.

Moore offers another example: In baking, a processor may have a divider that doesn’t measure each dough ball precisely. In this case, modifica-tions or improvements may need to be made

to the div ider to improve precision. But first, finished pack age weights w o u l d n e e d b e measured to deter-mine the baseline “giveaway” loss.

W hen it comes to c h a n g e o v e r s , not executing them e f f e c t i v e l y m a y result in more loss or “ bad” product being made from one run to another. But, implementingcontinuous improve ment meth-o d o l o g i e s a l o ng with software tech-

nologies to measure this data automatically can begin to shine a light on opportunity areas, adds Moore.

With complex systems, software can be an issue in itself. “Developing software to automate mate-rial deliveries can quickly become complicated when programming a process control system,” says Randy Otto, vice president of ECS Solutions, a member of the Control System Integrators Asso-ciation (CSIA). “Systems with valve clusters that allow ingredients to be sent to multiple vessels can complicate the software.” Common solutions to obtaining accurate deliveries include slowing the delivery of a material throughout the delivery cycle or toward the end of the delivery cycle (dribble flow or dribble speed). “Herein lies the issue,” con-tinues Otto. “The end-user must sacrifice speed [performance] to obtain quality. Overall yield is a product of performance and quality, so reduc-ing one to increase the other produces a minimal result. Yield is significantly improved when you can increase performance or quality while main-taining or increasing the other.”

“Performance issues are reflected back to yield and quality opportunities—and even more on high-speed production lines,” says Tom Braydich, senior consultant at Matrix Technologies, a mem-ber of CSIA. Some of the issues are improper line balancing to prevent surges and stoppages, ill-maintained equipment, product and material supplies (cans, bottles, cartons, labels, etc.).

Matrix Technologies can help with an overall equipment evaluation and modification of filling and packaging systems to ensure line coordination

to the div ider to improve precision. But first, finished pack age weights w o u l d n e e d b e measured to deter-mine the baseline “giveaway” loss.

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among OEM vendors. “When a line is designed so all the equipment operates as one coordinated unit [regardless of the OEMs involved], the throughput can increase dramatically,” adds Braydich. “Large improvements can be realized through a simple investment in automation for the overall line ver-sus the individual machines.”

Other issues also can complicate raw ingredients and formulation. “Production yield for a given for-mulation varies depending on the raw ingredients being used [e.g., the quantity of denatured proteins in milk affecting yield in cheese making],” says John Tertin, director of manufacturing informa-tion systems, ESE Inc., a member of CSIA. “Mak-ing in-process adjustments to account for variance in the raw materials can recover yield that would otherwise be lost in processing.”

Another issue related to measuring ingredients is the mating of piping with the flow meters in a system. “When adding new flow meters to improve data collection, we check the piping design to

improve the performance of the flow meters,” says Robin Cobb, project manager at Polytron, Inc. “We often find a piping design is not conducive to the best practices for measuring density set points.” Related to mass flow meters, Cobb suggests auto-mating density set points to ensure standardiza-tion of how density is measured, taking it out of the operator’s hands and guaranteeing accurate, apples-to-apples comparisons.

Another common issue is the control of product loss at transfer points, according to Arun Madan-garli, Polytron senior engineer. “In a beverage process, for example, loss typically occurs in two areas: the unit operations that are part of the process and during the transportation of product through the process line when it is transferred from one stage to the next. Over time, the loss at these points can be a significant amount.”

For a small operation, however, waste can be improved with relatively simple automation. For example, a bag filler can be automated with a

Quality Analytix software enables multiple staffing levels to view SPC data and other production parameters that affect product quality. The system leverages ICONICS Hyper Historian for its core data collection and calculations; its architecture supports enterprise-wide SPC quality programs, as well as applications that require very fast sample rates. Source:

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Many manufacturing plants don’t know they have quality/pro-duction yield issues until they implement various lean manufac-turing initiatives. Some of these issues include:

• The products are in spec (meeting the recipe for quality), but the filling process is not capable of being stable, e.g., over- and under-filling.

• No plant visualization—Operators have no real-time visual-ization of a control process and can only react to past events.

• Random defects such as product contamination, incomplete coating or enrobing.

• Systematic defects—Defects are predictable, based on past measurements.

• Lack of process knowledge—Operators adjust set points to compensate for new or perceived problems.

• First pass yield is low, and scrap/waste count is very high.• Not performing 100 percent inspection.• Not logging the correct critical parameters.• Environmental controls affect process quality.• Performing SQC only catches 80 percent of the defects. Changing to a real-time SPC solution can increase that per-

centage.

Source: Iconics.

Tackling previously untackled quality/production yield issues

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weigh scale and a small PLC and HMI in the same housing, according to Don Pham, IDEC product manager. The IDEC combined HMI+PLC unit provides the automatic cycle and process control required for a bag filler and frees up the opera-tor to tend to other plant operations. Variable fill rates and impeller speeds are controlled by the unit based on readings from the electronic weigh scale. The automation assures each bag will be filled to the correct level, without overfill.

Beyond the low-hanging fruitSometimes, figuring out what is causing a yield and/or quality problem can be difficult, but often, it is very process specific and can be tied in with ingredients. “If the product is baked, there may be issues around a consistent, thorough bake in the oven,” states GE’s Moore. “Another partially ambiguous loss area—or one that may be harder to pinpoint—is the

When reliable sensor data is needed to improve throughput and yield, slip rings on moving machinery are a constant maintenance headache. The Clever Sleever machine places and wraps decorative sleeves on bottles at a rate of 15,000 pieces per hour. To maintain data integrity, the machine builder installed ProSoft Technology Hotspot radios and radiating cable to move sensor data from rotating rounding tables to stationary terminal devices, increasing uptime and yield. Source: ProSoft Technology.

YOU’RE LOOKING AT TWO PRODUCTION LINES.CAN YOU SPOT THE DIFFERENCE?No? That’s because the difference between these two lines is their bottom lines. One produces 5% less waste and 8% more output. The manufacturer even added a SKU without adding another line, which lowers costs and maintenance needs. Just picture the possibilities for your operations.

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actual effect of varying raw material specifications on finished products. For example, in baking, slight fluctuations in protein in the flour [negative or positive] affect yield. This can be hard to determine if the specifications aren’t tied to the lot digitally.”

Incorporating actual raw material properties into the pro-duction process saves time and ensures product quality. “For example, in an extraction process, the amount of water need-ed to reach a desired finished product total acidity [TA] is dependent on the TA of the raw ingredient,” says ESE’s Tertin. “You could add about 80 percent of the water, test to deter-mine how much more is necessary and add the remainder. But, [if you incorporate the quantity and TA of the raw mate-rial into the process], you can add exactly the right amount of water to begin with and ensure consistent yield and save time in that portion of the process.”

Human factors, such as a lack of process knowledge, are additional considerations, according to Carl Harper, ICONICS project engineer. “Increasing set points to make production line or individual machines run more quickly to meet targets affects quality. But, without process knowledge, employees may believe, ‘If the line/equipment is running, we are in control, and all is well.’ Consequently, when it isn’t run-ning properly, nobody knows why or how to fix it.”

In addition, when working with dense products like soup, bread and cookie dough, end-of-line checkweighers can pro-

vide a false sense of control over product final weight, says Matrix Technologies’ Braydich. “The fluctuation of weights may be the result of recipe errors due to a faulty flow meter, scales or worker behavior. Whatever the cause, an operator will repeatedly adjust the filler or depositor weight all day long. The consumer will get the correct weight, but the qual-ity of the product will be the big question.”

Maintenance and control software also can have a positive or negative effect on yield. “Processors are becoming increas-ingly aware that reliability centered maintenance [RCM] can keep equipment in optimal operating condition and provide the highest availability [improving yield and meeting quality targets],” says Schneider’s Lemaire. “Technology developed and used in heavy industries is finding its way into food and beverage processing plants’ maintenance practices.” (For more on RCM and predictive maintenance, see “The future looks smarter,” FE, July 2015.)

Software solutionsControl software plays a big part in improving yield. How-ever, more obscure yield and quality problems frequently can be masked or made unattainable by just-average controller software, according to ECS Solutions’ Otto. “Controller soft-ware is only as good as the engineer who developed it, and often, the developer is under critical constraints [e.g., time,


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budget or scope issues] that prevent him or her from devel-oping the best solution. The controller software can become complicated, especially over time with multiple developers adding to it, creating greater challenges and barriers to make improvements to the system performance.”

Many processors turn to commercial off-the-shelf (COTS) software packages that log, analyze and report data in numer-ous ways to identify the greatest problems in a system. Otto says that while MES packages with these options promise great benefits, they are costly to purchase and implement. Plus, while they may identify areas of constraints, they sel-dom offer solutions. ECS has implemented numerous flexible solutions, replacing or enhancing controller software, and providing a means for end-users to optimize performance gradually. “Our customers have discovered low-hanging fruit they were unaware of, realizing performance increases of 20 to 40 percent, as well as improved quality and a 5 percent increase in availability,” concludes Otto.

Implementing a manufacturing intelligence solution enables long-term process improvements that can help make a plant more flexible and improve margins. “Tyson Foods was experiencing unacceptable variances in the weight of Hillshire Brands plastic-wrapped breakfast sausage, or ‘chubs,’ causing waste and rework,” recalls Rockwell’s Rao. “The

company turned to FactoryTalk software to better under-stand exactly where the variance issues were being created. This [software] update changed Tyson’s available data from an ex post facto report on how much waste was produced to dynamic, real-time data on weight fluctuations along the line, the exact giveaways on finished product, machine downtime, OEE and meat temperature. The plant ultimately saw an increase in yield of 0.50 percent, which is more than half a million pounds of sausage annually.”

Methods and procedures to find yield problemsWhat methods or systems should processors employ to find and fix yield issues? “First and foremost, are the collection of key information [set points, temperatures, weights, flows, counts, etc.] in the process and linking it by time, schedule and batch,” says Braydich. “Simple SPC [statistical process control] methods like upper and lower control limits applied against the data will identify variation in blending and batch-ing processes.” Braydich reports food processors realizing ROIs from 20 to 30 percent. Typically, yield improvements precipitate savings in other areas like OEE.

Using SPC helps operators monitor processes in real time and reveals process variations including out-of-control and trend issues, says ICONICS’ Harper. In addition, perform-

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ing 100 percent inspections allows users to capture and store more data. SPC informs operators of process stability and capability by exposing key metrics like Cpk (process capabil-ity) and Ppk (process performance). Harper also suggests implementing a solution for Six Sigma, ISO 9000 and Total Quality Management (TQM) initiatives. In addition, using fault detection and diagnostics (FDD) technology helps identify faults in the process (e.g., an oven temperature great-er than x° for five seconds). An FDD solution can also point out energy surges and detect how many times they occur.

A mass-balance reporting system that encompasses the entire production line (from bulk material intake to finished product storage) is another method that can track and quan-tify product loss, says Polytron’s Madangarli. “While a typical report measures yield in terms of units relevant to the cor-responding process area [gallons, cases, bottles, etc.], mass-balance reports compute yield in units of mass [lbs. or kg]. This gives a much more accurate picture of the process yield, especially if a precise, real-time measurement of the product density is available.”

ESE’s Tertin recommends using advanced control techniques and inline instrumentation plus maximizing data integration between the ERP/MES and control system layers—either directly (in a non-isolated networked environment) or by the

use of barcodes/RFID tags. SPC calculations are part of ESE’s Q5 analytical software package. One Midwest cheese proces-sor achieved a complete payback on a Q5 analyzer in 150 days, based on QC consumables and lab hard-cost savings.

“For material deliveries within process systems, ECS uses statistical spill value tracking to meter every ingredient to every location,” explains Otto. “With this method, we can not only substantially increase accuracies in material deliveries, which improves quality, but also increase yield by calculating a very accurate spill value at full speed.” By employing this method, one food processor recently realized a 30 percent increase in performance, improved quality and a 5 percent greater equipment availability.

“Advanced process control [APC] and model predictive control [MPC] are effective in increasing process yield and reducing out-of-spec product at the beginning and end of a process run,” says Emerson’s Pozarski. “Precision measure-ments can decrease overfill without risking under-fill in pack-aging and filling applications.”

While APC or MPC applications aren’t for everybody, they can be very effective in certain applications. According to Pozarski, a major brewery reduced beer loss by 1 percent, sav-ing over $70,000 per 1 million barrels brewed, by identifying the unexpected loss of yield in a process unit and correcting


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the root cause. In another case, a bev-erage processor eliminated a process bottleneck in its mix room, increasing available capacity by a factor of four, by updating its traditional batch weigh sys-tem to one that simultaneously blends liquid components into the mix tank through precision flow meters.

“Many software packages that may provide incremental value have different capabilities including SPC and non-conformance management,” says GE’s Moore. “But, the fundamental priority for a manufacturer is to make sure the system is built on an open platform to be able to access the data and work with

other systems for scalability and repeat-ability purposes. A standalone, disparate system may provide initial value, but over time, the cost to manage and maintain another system outweighs the benefits.”

Prepare for improving yieldSensors are at the edge (or periphery) of holistic systems that measure plant operations, says Schneider’s Lemaire. They sense and measure the process and primarily detect when things go wrong.

At a minimum, control systems, as well as some automation and instru-mentation, should be installed wherever possible, observes Moore. A processor must be able to measure product flow as it moves throughout the entire process. Software can then be added to aggregate and correlate that data and information.

In many applications, weigh scales can be upgraded or replaced to obtain this data, says Braydich. Plus, flow meters can both improve throughput and increase accuracy in batch applications. When materials can be added simulta-neously, batch time can be reduced sig-nificantly while improving consistency between the batches.

According to Tertin, depending on the process area, additional hardware may include analytical instrumentation, 2D barcoding systems, Coriolis flow meters, proximity sensors and smart devices such as Ethernet-connected VFDs, weight controllers, load cells, X-ray systems and metal detectors.

Fortunately, new systems come with sensing devices, but sometimes, they require a little adjustment. For example, ECS’s Otto describes a recent optimiza-tion of a bourbon bottling line: “The optimization required software chang-es and moving existing bottle sensors around on the line to increase perfor-mance and quality. New and additional VFDs and sensors were recommended to help reduce impacts of the glass bottles and further optimize the performance.”

Integrating sensors with process control systems also improves a system’s perfor-mance. Otto notes that one CIP system delivered by ECS with integrated sensors

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and software helped the end-user reduce CIP time from 13 hours per week to four hours per week, improving the availabil-ity and yield of the process equipment.

Is historical data needed?One final question: Does a proces-sor need a repository of archived pro-

cess data to install software systems that can monitor yield and performance? “Historical data will always be helpful in implementing new systems, although new systems for improving yield have been implemented without it,” answers Rockwell’s Rao. What makes historical data significant is its ability to provide

context to the improvements made by a new system. For instance, historical data can set a good baseline for understanding how much value a project will add.

“ Without ‘ hard’ data , there w i l l always be a certain amount of conjec-ture regarding the potential gain [of a new project],” says Tertin. “For some customers, this is acceptable, given their desire for short-term, incremental improvement; for others, it is not.”

Historical data can be used to compare improvements made by automating a particular work step. For instance, with a bagging machine, the data could include the amount of labor necessary to operate it manually, the required rework from operator errors and the reduced through-put due to waiting on required operator actions, according to IDEC’s Pham.

GE’s Moore suggests that while a proces-sor does not need to have any historical data to begin implementing a system, reviewing the data should be the first step in looking at technology to aid yield improvement. A processor should ask three questions about collected data before embarking on this process: Am I collecting meaningful data? Do I have a strategy to store and access the data I collect? Have I prioritized the out-comes I desire? ❖

For more information:Eric Lemaire, Schneider Electric, 949-727-3200, eric-s.

[email protected], www.schneider-electric.com

Arvind Rao, Rockwell Automation, 440-646-3434,

[email protected], www.rockwellautomation.com

John Tertin, ESE Inc., 715-387-4778, [email protected],

www.ese1.com

Katie Moore, GE Intelligent Platforms, 800-433-2682,

[email protected], www.ge.com

Randy Otto, ECS Solutions, 812-479-5170,

[email protected], www.ecssolutions.com

Robin Cobb, Polytron Inc., 855-794-7659,

[email protected], www.polytron.com

Arun Madangarli, Polytron Inc., 855-794-7659,

[email protected], www.polytron.com

Tom Braydich, Matrix Technologies, 419-897-7200, ext. 306,

[email protected], www.matrixti.com

Don Pham, IDEC, 408-747-0550, [email protected],

www.idec.com

Carl Harper, ICONICS, 508-543-8600,

[email protected], www.iconics.com

Ron Pozarski, Emerson Process Management, 952-828-

3434, [email protected], www.emersonprocess.com

Frank Tappen, DataNet Quality Systems, 248-447-0120,

[email protected]; www.winspc.com

Dave Boeldt, Bosch Rexroth, 1-800-REXROTH, dave.

[email protected]; www.boschrexroth.com

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T E C H U P D A T E : FILLING EQUIPMENTDebra Schug, Features Editor

lame social media, changing tastes and needs or just the “Have it your way” atti-tude inspired by Burger King’s decades-long slogan, but modern consumers are

demanding. In fact, a recent GNT Group study reports two-thirds of shoppers are checking the labels of food and beverage packages before pur-chasing the products, and the majority of these con-sumers are ensuring the products have no artificial additives or preservatives.

According to Innova Market Insights, the number one trend of 2015 is “From Clean to Clear Label,” which underscores the growing demand for more naturally based food and beverage products. Food

processors are responding; companies like General Mills and Kraft continue to announce they are rid-ding their products of artificial flavors.

“Food and beverage companies are certainly look-ing for ways to tap into the clean eating trend,” says Roberto Mastri, technical support and quality direc-tor of North, Central and South America for Tetra Pak. “And, that’s impacting how manufacturers are looking at processing and packaging technologies.”

Moreover, today’s consumers are looking for a wider variety of foods and beverages in an assort-ment of flavors and a number of different sizes. With all of these rapid changes in consumers’ prefer-ences, food and beverage producers must be able

The SIG Combibloc high-speed filling machine requires almost the same space and manpower as previous models, but has six tracks instead of the previous four. Source:

SIG Combibloc.

B

Meeting great expectations As consumers want a bigger variety of healthier choices that come in a plethora of sizes, manufacturers are offering fillers that are flexible while producing optimal output.


T E C H U P D A T E

to respond to trends quickly. Thus, the flexibility of filling machines has become a crucial part of the production line—equipment that can handle differ-ent products filled into various types of containers without sacrificing accuracy or speed.

Improved product flexibilitySome processors looking to offer more natural foods and beverages are increasingly turning to aseptic processing. In fact, the aseptic market has grown 9 percent annually and is estimated to be worth over $35 billion, according to research by The Freedonia Group.

“As consumers continue to analyze ingredient panels, we see a growing demand for products that don’t contain added chemicals or preservatives,” says Mastri. “Aseptic processing and packaging meet this demand by protecting food and beverages with-out the need for these additives.”

According to Mastri, processors should take into consideration the types of foods and beverages they process and consider their impact on the final prod-uct. For example, tea is a naturally alkaline product that can be processed using high-acid hot fill, but aseptic is a much better match.

“Rather than adding acid and masking that bit-terness with sweeteners as you would with a hot fill process, aseptic processing enables the cleanest possible label for packaged shelf-stable tea: tea plus water,” Mastri explains.

SIG Combibloc offers aseptic food filling machines that accommodate a wide variety of foods, such as liq-

uids or foods with a pasty or chunky consistency that can be packaged with long shelf lives. The machines can aseptically fill into carton packs food products containing particulates up to 25mm in length and with up to 50 percent particulate content.

These types of filling machines are important since one of the changes in product formulations spurred by a focus on healthier foods, as well as manufacturers’ efforts to differ-entiate brands, is the call for larger, better defined particulates in prod-ucts. “These types of [more natural] products are typically much thicker in viscosity,” observes Rod Gregg, vice president of sales for Hinds-Bock. “Without the right options on the machines, these products can be trou-blesome for a filler.”

Food products with a very high particulate content have difficulty flowing freely and passing through a pumping system and an aseptic process. For these kinds of products, SIG Combi-bloc offers the heat-resistant, retortable combisafe carton pack. This system uses three modular filling units with a high-precision multi-head weigher. The three-stage filling technology allows varying sizes and quantities of an ingredient to be added accord-ing to user specifications.

Precision and accuracy are still top of mind for processors. “Particulate product damage and drain weight inconsistencies are not tolerated anymore,” says Jan Sundberg, application development man-ager for JBT Food Technology. “This has led to requests for new types of fillers to obtain previously unreachable goals.”

With this in mind, JBT created the Unifiller unit, which has large porting and short product paths to handle much larger particulates without damaging them. Additionally, the cutoff points have been reduced to ensure the product is dosed accurately into containers. The combination of features allows the unit to handle 50 to 60 percent solid content of very large particulates without any issues.

Additionally, due to the demand for wider ranges, fillers need to be able to handle an entire variety of high-viscosity, large-particulate products, as well as water-like products, without making modifications to the equipment.

“The JBT Unifiller design is well suited for this type of large product range and can fill cold and hot, all on the same filling machine,” Sundberg says.

The JBT rotary, volumetric Unifiller unit is designed for accurate filling with fast and efficient product changeovers. The clean-in-place feature makes disassembly and manual cleaning unnecessary. Source: JBT Food

Tech.


T E C H U P D A T E

“There is no more need to use two different types of fillers and filling concepts.”

Improved packaging flexibilityProcessors looking to differentiate their products on an increasingly cluttered retail shelf are using more creative packaging. However, different types of con-tainers can affect line operation.

“As a filling company, you need to get the product into the container,” states Timm Johnson, vice presi-dent of sales and marketing for Spee-Dee Packaging Machinery. “Odd-shaped containers, small open-ings, small pouch sizes and handles can all affect the way products are filled.”

He notes that, in particular, smaller openings of containers can be difficult to work with since they limit the speed at which a product can be filled.

“Different package shapes or packages with small-er overall dimensions need very special features on the filling machines and specifically the filling nozzles,” explains Hinds-Bock’s Gregg.

He says Hinds-Bock fillers with adjustable nozzles connected to their traveling or diving spout bridges work with several different packaging center lines.

“Filling lines are now designed with considerations for future unique packaging flexibility,” says JBT’s Sundberg. “A single filler has to be able to handle all sorts of containers, such as glass, plastic, cans and bottles. Optional ‘quick container change parts’ are becoming standard in these kinds of applications.”

These easily adjustable parts are important for reducing changeover time to less than 10 minutes and involve just one person. Additionally, automation is playing a role in handling different package sizes.

“With the latest PLC [programmable logic con-troller], fillers can store multiple package recipes and, through servo motors, can automatically adjust to the correct full weight or number of times the filler needs to cycle in each respective package,” Gregg says.

To help food and beverage manufacturers keep production nimble and cost effective, SIG Combi-bloc has focused on the flexibility of its filling lines, says Heike Thevis, communications officer. Proces-sors can use one filling machine to fill carton packs with different formats, if they have the same base dimensions.

“This can be done in a range of different vol-umes and with any required design,” adds Thevis, “enabling a processor to position products opti-mally, in exactly the right way to suit the market and the target group in each case.”

For example, soup in a one-liter family carton pack and a smaller volume size geared toward a single-person household can be processed by one Combibloc filling machine; up to seven different volumes can be filled.

At this year’s Anuga FoodTec Show, Bosch Pack-aging Technology presented its Ampack AF 8/8 inline cup filling machine, which features a pulsed light decontamination system for ultra-clean appli-cations. Jonathon Titterton, director of sales and marketing for Bosch, says the equipment offers more format flexibility for different cup shapes and sizes by using preassembled cell plates for two dif-ferent diameters. It also reduces changeover time to 15 minutes.

Continuing need for speed and efficiencyMore than a decade ago, servo-driven fillers began replacing older, pneumatically driven machines. “Servo-driven fillers are much faster than conven-tional pneumatic fillers as they have no suction stroke. They are always primed ready to cycle and fill the package,” explains Hinds-Bock’s Gregg. “The pneumatically driven fillers have a suction stroke to prime the product cylinder prior to the discharge stroke, taking much more time to fill a package.”

However, as important as the filling line speed is, output and efficiency are the criteria more companies are focusing on. “Globally, improving plant performance to make production as efficient as possible and ensure long-term presence in the market is of paramount concern for filling com-

With the food industry demanding more hygienic designs to ease contamination concerns, Hinds-Bock introduced its new 8P-06 Ultra-Hygienic filler. Source: Hinds-Bock.

T E C H U P D A T E


Innovative Packaging Solutions The better alternative for over 20 years.

www.harpak-ulma.com (800) 813-6644

panies,” Thevis says. With servo drives and a total of six tracks, SIG Combibloc’s new aseptic filling machine can fill 24,000 carton packs per hour, making it the fastest for 125 to 350ml packages.

Also important to efficiency is avoiding product giveaway by ensuring each valve and component works to identically fill every container. “Continued operation at a high accuracy level is often something processors do not consider when buying a filler, but it is probably one of the most important factors to look at,” offers Sundberg. He explains a simple, seal-less design with fewer moving parts that can wear down is needed for reliably accurate volumetric fillers. “For example, an accuracy of less than 0.1 to 0.4g per standard deviation is becoming the new sustained norm.”

Another way some filling equipment manufacturers are speeding up the line is through innovations in package sterilization. For instance, Tetra Pak recently launched a new filling machine that uses electron beams, not hydrogen peroxide, to sterilize packaging material.

“The Tetra Pak E3 eBeam filler removes a long-time physical limitation to carton packaging speed: the hydro-gen peroxide sterilization process,” says Mastri. “With the machine, speeds of up to 40,000 portion packs per hour, or 11 packs every second, can be achieved.”

Market tests conducted by Tetra Pak showed this increased capacity can save beverage manufacturers 20 percent in operational costs and improve environmental performance by making water recycling easier, lowering energy consumption and cutting waste.

Sanitary design and automationFacing more pressure and further regulations concern-ing food safety and contamination prevention, food and beverage processors need more hygienic designs of filling

SIG Combibloc equipment allows switching between different fill volumes in minutes, making it easier to create products tailored to specific target groups. Source: SIG

Combibloc.


T E C H U P D A T E

machines. A number of manufacturers are answer-ing the call by offering equipment that is easier to clean and break down.

For example, Hinds-Bock recently introduced the 8P-06 Ultra-Hygienic filler, which has stain-less steel enclosures and minimizes flat surfaces by using slope-top covers. The tubular frame allows easier cleaning of all the filler’s parts, while the tilt hopper provides access to the product ports. Wire looms separate all wiring and air lines, which can be quickly disconnected for faster setups and teardowns.

Some filler manufacturers are employing auto-mated cleaning processes such as clean-in-place (CIP). Recent improvements are aimed at reducing overall cleaning time, as well as water, chemical and energy usage.

“New two-stage CIP cleaning with complement-ing dual chemicals is the latest trend to reduce clean-ing time and overall energy usage,” says Sundberg. “Performing CIP at lower temperatures decreases overall cleaning time by reducing ramp-up and ramp-down times.”

Automating the cleaning process also ensures the final sanitary condition of the machine and minimizes the use of chemicals by recirculating and reusing them in the process.

“A higher level of hygienic design allows extended runs between cleanings and is very important in 24/7 operations,” continues Sundberg. “Performing CIP only once a week, instead of daily, is becoming more and more prevalent.”

Advancements in automated technology are improving operation in other areas as well. For instance, SIG Combibloc offers the R-CAM robotic magazine that automatically opens and removes carton sleeve shipping boxes and loads a filling machine without employee involvement.

The robotic magazine basically consists of two modules: a pallet magazine and an unpacking sta-tion. The pallet magazine offers space for a Euro pallet, industrial pallet or Australian pallet. Once a pallet is inside the magazine, a scanner records the arrangement of the shipping boxes on the pal-let, and the gripper arm moves a shipping box to the unpacking station. An internal buffer provides continuous, smooth operation, even while a new pallet is being loaded into the pallet magazine. The buffer can accommodate up to 20 shipping boxes of carton sleeves. The magazine can operate for up to 2.5 hours without the need for a new pallet. Inside

To ensure accurate filling and gentle product handling, the Unifiller machine’s design, number of valves, nozzles and other parts are custom-fit to suit specific product requirements and the necessary line speed. Source: JBT

Food Tech.

Jonathon Titterton, director of sales and marketing for Bosch Packaging Technology, says the company saw the need to pro-vide processors with tools to create more shelf differentiation and enhanced consumer convenience. To fill this need, Bosch now offers a continuous motion bagger that produces up to 100 high-quality doy-style bags per minute with a zipper reclo-sure. The SVE 2520 DZ machine helps snack and confectionery manufacturers boost shelf appeal and offer reclosable features while increasing production efficiency.

At six square meters—one-third the required space for an equivalent horizontal pouch machine—the Bosch bagger offers up to 50 percent higher output per square meter. It can also produce other common bag styles such as pillow, gusseted, block bottom, corner seal, full corner and three-side sealed.

The SVE technology is designed for easy operation and main-tenance; changeover from pillow to the Bosch Doy Zip bag takes less than an hour, according to Titterton.

Bosch offers its SVC platform for fresh and frozen food producers. The hygienic design is especially suitable for manu-facturers that must comply with more stringent food handling regulations. It offers quicker setup and tool-less changeovers and can handle pillow, gusseted and corner seal pack bags.

Engineered for brand marketers utilizing stand-up pack styles, the new corner seal option will be launched at PACK EXPO Las Vegas 2015. The option can be integrated into the existing SVC machine and enables frozen foods manufactur-ers to use film material other than the standard polyethylene traditionally applied for pillow bags.

Vertical form/fill/seal offerings

T E C H U P D A T E


the unpacking station, the shipping boxes are opened, and the sleeves are removed from the box. The sleeves are automati-cally filled into the appropriate track of the filling machine, and the shipping boxes are folded flat and collected in a specially provided container for subsequent disposal.

“The robotic magazine is a key component in building the fully automated filling line of the future, in which automatic guided vehicles [AGVs] transport pallets of packaging material automatically from a central store to the R-CAM unit,” says Jan Gansow, global product manager at SIG Combibloc. “It’s a major step toward the ‘smart factories’ of tomorrow.”

Currently, the robotic magazine is available for the CFA 724 high-speed filling machine for products in the small-size combibloc carton format. The first R-CAM 724 prototype is in operation at Arla Foods Germany in its Pronsfeld factory. ❖

For more information:Heike Thevis, SIG Combibiloc, 0049-2462-79-0, [email protected], www.sig.bizJan Sundberg, JBT Corporation, 559-661-3200, [email protected], www.jbtfoodtech.comJonathon Titterton, Bosch Packaging Technology, Inc., 715-246-6511, [email protected], www.boschpackaging.comLarine Urbina, Tetra Pak, 940-380-4630, [email protected], www.tetrapakusa.comRod Gregg, Hinds-Bock, 425-885-1183, [email protected], www.hinds-bock.comTimm Johnson, Spee-Dee Packaging Machinery, 262-886-4402, [email protected], www.spee-dee.com

Hinds-Bock single- or multiple-spout/pump models can be used for a wide range of flowable products. The servo controller allows quick, easy changeovers, and the sanitary pumps are CIP-able. Source: Hinds-Bock.

F I E L D R E P O R T S


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and Source Technology – innovators of inline sampling and analysis equipment, fully integrated

with Wenger’s automation for total system communication.

Rally the power of three to address the entire scope of your extrusion-based project. You’ll

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corporateprojectservices.com sourcetechnology.dk wenger.comSee us at Pack Expo Booth #58447!

Precision weighing technology increases accuracy

When the University of Wisconsin’s dairy department updated its mixing system, the switch to load cells helped produce a more consistent product.

T he University of Wisconsin-Madison Babcock Hall Dairy Plant uses a hands-on approach to research and teach cutting-edge dairy science techniques

to its food science students. The plant also turns 2 million pounds of locally sourced milk, includ-ing some from the university’s own herds, into ice cream, yogurt, fluid milk products, butter, cheese and fermented products.

The plant was built in 1951, making it the old-est university dairy building in the US. Planning is underway to fully renovate the factory by 2018 and outfit it with the latest industrial technologies. Part

of this renovation is the updating of the old mix pro-cessing vats, switching from side-mounted pressure gauges to load cells for monitoring and controlling manufacturing processes. The production method requires monitoring the level of each ingredient before it is added to a mixing vat and then passed along the production line.

“In the past, we measured the liquid levels either by pressure sensors or measuring sticks and had to adjust for product density,” explains Plant Manager Bill Klein.

Load cells were recommended due to their poten-tial for greater accuracy, producing more consistent


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ingredient mixtures and cost-effectiveness. The tanks the plant chose were designed and built by Sprinkman Corporation; the load cells were supplied by Sartorius Intec, a manufacturer of industrial technologies headquartered in Ham-burg, Germany.

The Sartorius Intec PR 6211 compression load cell was chosen in conjunction with a PR6011 flex-lock mounting kit to fulfill the plant’s requirements. Available in versions from 500kg to 10t, the cell is fully constructed from stainless steel and allows for calibration without weights, simplifying the installation. The X5 system controller was installed alongside the load cells and mounting kits to accurately con-trol the plant’s manufacturing processes.

Using precision weighing technology in pro-duction processes offers manufacturers the chance to greatly increase the accuracy of their

systems and reduce product give-away and inconsistencies. Babcock Hall Dairy Plant’s original system relied on volume; however, with a range of products at varying densi-ties, a conversion was necessary to reliably calculate how much prod-uct was required. In the past, as soon as the levels in the 600-gallon vat dropped below 100 gallons, the accuracy of the whole system was reduced, causing large discrepan-cies in the end product. However, this no longer happens with the upgrades.

“We have found that using load cells is far more accurate, sanitary, faster and altogether easier,” says Klein. “We hope to add load cells to additional vats in the future.” ❖

For more information:

Chad Stedman, 720-431-6985,

[email protected],

www.sartorius-intec.com.

The three-legged tank system uses a compression load cell, in combination with a flex-lock mounting kit and process controller capable of developing and storing multiple recipes. Source: Sartorius Intec.

F I E L D R E P O R T S


Sanitary, reliable drum motor drives success

Poultry processor strives to meet customer demands without sacrificing the highest hygienic standards, so minimizing downtime is a must.

A custom food processor, AlaTrade Foods provides large poultry processors with a service that requires intensive amounts of labor. AlaTrade Foods takes in the

front-halves of chickens and debones and disassem-bles products based on customer specifications—whether it is for the breast meat, wings, tenders or dark meat. AlaTrade debones approximately 1 million fronts (approximately 2 million pounds) a week.

To meet customers’ requests while maintaining sani-tation standards, AlaTrade leverages process efficien-cies, cutting-edge technologies and superior customer

service, which results in better quality, better yield and better response times for customers.

To minimize downtime and reduce maintenance costs, AlaTrade employs a Van der Graaf drum motor to drive its conveyors. The company started working with Van der Graaf over a decade ago when it was looking to solve internal failures on conventional conveyors.

“Since then, we have seen the potential for us to limit our amount of downtime and create a safer work environment,” says Kevin W. Parnell, plant manager for Alatrade Foods LLC. “Being a player in the poultry industry, we believe food safety is—has


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to be—at the top of our priority list. Van der Graaf plays a huge role in us doing that.”

Industry requirements demand all chicken processors exceed food hygiene standards; thus, the highest level of sanitation must be maintained. The overall construction and engineering behind the Van der Graaf drum motor is intrinsically hygienic to address sanitation requirements.

“The VDG motor withstands 3,000 psi of water pressure, preventing the harboring of bacteria and other contaminants,” explains Ray Hayes, quality control supervisor for AlaTrade Foods LLC, “so we can wash things quickly, apply our chemicals to kill the microbes and get back up and running again. In any manufacturing environment, downtime is money.”

The engineered design of the drum motor puts all the working components to power the conveyor inside the roller of the head pulley. “Van der Graaf is the best in the industry as far as the con-cise fit of the motor and the reduced room it takes up,” says Hayes.

The motor’s mechanical components are in a constant food- grade oil bath, which allows it to have a maintenance interval of 50,000 hours between oil changes. With nothing external and, therefore, nothing subjected to the working environment, a drum motor outlasts a conventional drive, while offering reduced downtime and lower maintenance costs.

“From a management standpoint, having something that is not going to fail allows you to focus on other things that

improve your process instead of worrying about whether a motor is going to go out,” says Parnell. ❖

For more information:

Melissa Lara, 888-326-1476, [email protected],

www.vandergraaf.com/improvesanitation.

The Van der Graaf drum motor is a one-component conveyor drive, with the motor, gear drive and all moving parts enclosed inside the drum. Source: AlaTrade Foods.


ver the 20 years of its existence, PACK EXPO Las Vegas has grown from a regional show to one of the most expansive events for packaging and process-ing innovation. This year, the show will feature more than 800,000 net sq. ft. of exhibit space.

PMMI anticipates the attendance this year will reach near 30,000, and the event will attract over 2,000 exhibitors, includ-ing industry leaders that serve more than 40 vertical markets. It will include the Las Vegas debut of Pharma EXPO, jointly produced by PMMI and the International Society for Phar-maceutical Engineering (ISPE). “PACK EXPO shows have evolved alongside the needs of attendees and exhibitors, and we’ve come a long way from where we started,” says Charles D. Yuska, president and CEO of PMMI.

In 1995, PMMI introduced the industry to PACK EXPO West, featuring packaging equipment from 532 exhibitors and attracting 9,334 attendees. Exhibit space was approximately 200,000 net sq. ft.—about 25 percent of this year’s event. The international flavor of the show has grown as well. While visi-tors from outside the US made up 8.3 percent of the attendee base in 1995, they accounted for 18 percent at the most recent event in 2013. The number of international exhibitors also has increased from just 54 at the debut PACK EXPO Las Vegas to more than 310 expected for this year’s event.

PACK EXPO Las Vegas will be bringing back its Innova-tion Stage, which will occupy three different spaces. All the stages will offer free, 30-minute educational sessions running concurrently throughout each day of the show. Attendees can also learn about new technologies in seminars at the Food Safety Summit Resource Center and the Center for Trends and Technology: Improving Production Through Innova-tion, sponsored by Rockwell Automation and its PartnerNet-work Program.

To help attendees maximize their time at the show, industry-specific lounges and specialized pavilions, such as The Brand Zone, will provide access to current developments in specific

market niches. The Biscuit and Cracker Manufacturers’ Asso-ciation (B&CMA) will host the Baking–Snack Break Lounge. The International Society of Beverage Technologists (ISBT) will be providing resources at The Beverage Cooler Lounge, designed for beverage industry professionals to network and learn about solutions from ISBT subject matter experts.

PACK gives BACK will take place on Monday, September 28 at 4:00 p.m. featuring the band Chicago. Tickets for the show are $100 each and are available to all industry professionals. A portion of this year’s ticket sales will support the Fisher House Foundation, best known for providing a network of homes where families of injured veterans can stay for free while their loved ones are receiving medical treatment.

“Over the years, we’ve added features and events, but one thing hasn’t changed,” Yuska says. “PACK EXPO Las Vegas is a venue where industry professionals come together, do business and find the solutions they need for operational excellence.” ❖

PACK EXPO Las Vegas 2015 at a glance} Where: Las Vegas Convention Center

} When: Monday, September 28, 2015 through Wednesday, September 30, 2015

} Exhibit Hours: 9:00 a.m to 4:00 p.m. Monday through Wednesday

} Contact: 571-612-3200 or packexpolasvegas.com

O} PMMI expects the 2015 event will be triple the size of 1995’s inaugural PACK EXPO West. Source: PMMI.

Industry show celebrates its20th anniversary

PACK EXPO Las Vegas Preview

PMMI, the Association for Packaging and Processing Technologies, produces the largest-ever edition of its Las Vegas show.


SPECIAL ADVERTISING SECTION

2015 PACK EXPO LAS VEGASSHOW PREVIEWS

ALLPAX

Contact:Greg Jacob

Allpax Products

13510 Seymour Meyers Blvd.

Covington, LA 70433

Phone: (888) 893-9277

Fax: (985) 893-9477

Web: www.Allpax.com

Email: [email protected]

See us at PACK EXPO Booth C-2818

If it’s in the Retort Room, WE’VE DONE IT!Allpax Products, powered by Pro Mach, designs, manufactures, and

supports customized retorts for in�container sterilization of packaged foods

and beverages. Allpax also designs automated material handling systems to

load, unload, and transport product before and after processing.

Allpax is the leader

in bringing new

batch sterilization

technologies to the

market. We specialize

is manufacturing

customized solutions

for in-container

sterilization using the

latest technology to

provide our customers

the highest quality

products combined with cycle time reductions. We offer turn-key solutions

for both sterilization and material handling. At Allpax, we design the line

around your containers to provide customized equipment that maximizes

efficiency.

We will be at Pack

Expo Last Vegas

showcasing our latest

retort and pasteurization

technology along with

energy management

controls solutions.

We hope that you will

take the time to visit

us at booth C-2818 to

discuss your retort sterilization and material handling needs because if it is in

the retort room, we’ve done it.

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 five plants in Stratford, Wisconsin, with over 175,000 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 400 associates and become a strategic supplier to many Fortune 500 Companies in the pharmaceutical/personal care, food/beverage, dairy, and indus-trial/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 in-house staff of design and automation engineers, welders, fitters, QA/QC profes-sionals and project management personnel.

From concept to completion, A&B can ensure your success through every phase.

Contact:Andrea Wiese

201 S. Wisconsin Ave.

Stratford, WI 54484

Phone: 715-687-4332

Fax: 715-687-3225

www.abprocess.com

See us at PACK EXPO Booth # 7404




Beckhoff Debuts CP32xx Series: Pole-Mountable Multi-touch Panel PCs

with Multi-core Power

With the new CP32xx Panel PC series from Beckhoff Automation, industrial

multi-touch display technology can now be used in an all-in-one, high-

performance automation device for HMI and control applications. These

powerful devices for mounting arm installation feature all-around IP 65

protection and integrate best-in-class multi-touch Control Panel technology

with a hig h-performance Industrial PC (IPC)- all in one rugged, yet compact

housing.

The area at the rear of the CP32xx Panel PC, which is required for swiveling

and tilting the connected mounting arm, is also efficiently used to accom-

modate the added IPC components while saving space. The components

in this solution are thermally decoupled from each other; to save space,

the computer is actually built around the integrated mounting arm in a

u-shaped housing with cooling fins for passive cooling.

Another advantage is the excellent heat dissipation characteristics despite

the compact design, achieved using internal fans; this ensures even tem-

perature distribution to all walls of the housing. This results in an impressive

operating temperature range from 0 to 45 °C. Moreover, all components

and connectors are easily accessible, which is convenient when using

removable storage media such as a CFast card or SSD.

Beckhoff Automation

Contact: Beckhoff Automation LLC

13130 Dakota Ave

Savage, MN 55378

Phone: 952-890-0000

Fax: 952-890-2888

e-mail: [email protected]

www.beckhoffautomation.com

PACK EXPO Las Vegas 2015 Booth #S-6163, Lower South Hall

Compressors is showcasing

its newest game changing

technology at the 2015 PACK

EXPO show. The products on

display are perfectly matched

for the processing and

packaging industry.

Among these products is the

newly released GHSVSD+

range of oil-sealed rotary

screw vacuum pumps that

feature quiet operation, and

state-of-the-art variable

speed drive technology. These

vacuum pumps consume

approximately 50% less energy

than alternative technologies. Visitors will also have the opportunity to

interact with the highly reliable GAVSD+ range compressors. This innovative

compressor reduces energy consumption and allows for a compact footprint

and low noise levels.

Atlas Copco Compressors is an industry-leading global manufacturer and

service provider of compressed air technology and quality air accessories

with 24/7 service support.

Atlas Copco

Contact:[email protected]

866-688-9611

www.atlascopco.us




Bunting

For more information on Bunting® Magnetics Co., call +1-800-835-2526 (in U.S. & Canada) or +44 (0) 1442 875081 in Europe or visit our web site at www.buntingmagnetics.comSee us at PACK EXPO booth # 5907

For more than 50 years, Bunting Magnetics Co. has developed and manufactured precision magnetic products for the worldwide printing, automobile, plastics, food, electronics and recycling industries.

The most common of foreign material within food

processing is metal. This contamination can cause damage to further processing equipment, but is also a safety hazard for consumers. Metal contamination that makes it into the food supply can cause untold brand and reputation damage to the supplier. Bunting® Metal Detectors sense and remove the presence of ferrous, non-ferrous and stainless metals in a process flow, or as a packaged item. These units can also find metal encapsulated in the individual food particle.

Successful detection and separation of metal will protect your processing equipment from damage, which saves your organization money and down time. Assuring the highest product quality and absence of metal contamination in your product, protects your reputation, and keeps you viable in the market.

Bunting’s extensive line of magnetic separation equipment removes metal contaminants from dry particulates, liquids, and slurries. Our lineup includes units designed to remove metal contamination from gravity, mechanical, or pneumatic conveying systems. Our specially built sanitary-grade metal separators are the first separators to earn USDA, AMS-Acceptance. Our engineers refined existing designs to help processors meet increased marketplace demands and governmental requirements for safer and purer foodstuffs.

You can rely on our equipment and expertise to eliminate product contamination and damage to machinery from tramp metal in an economical and cost-effective way.

134 October 2014 | Food Engineering | www.foodengineeringmag.com

2014 PACK EXPO INT’LShow Previews

ADVERTISEMENT

For more information call 316-284-2020, email [email protected]

or visit our website at www.buntingmagnetics.com.

See us at PACK EXPO International booth # 5516

For over 50 years, Bunting® has established itself as an industry-leading

manufacturer in several product lines. Since our founding, we have been

solving problems with magnetic energy

for manufacturers of everything from

paper towels and cardboard boxes to

automobiles, plastic housewares, food

products, and electronic equipment.

At this years Process Expo show we

will be featuring equipment from our

metal detection and magnetic separation

lines. Our meTRON 07 CI metal

detector has the latest in electronics,

aptly named, imagePHASE and is the

newest product recognition software

in the world. imagePHASE allows for

greater sensitivities and fewer false rejects. This combined with our DCM

washdown conveyor ensures your product will be free from contamination

as it moves down the line.

From our magnetic separation equipment we will feature our popular

Center-Flow magnet (CFM). Our CFM has been redesigned for easy and

quick cleaning capability. Bunting Center-Flow Magnets are designed to

handle materials that are non-abrasive or not subject to damage by impact.

It can be installed easily in any position or angle with factory supplied

compression couplings. This product is ideal for use in dilute-phase

pneumatic conveyor systems.

BuntingBimba

Bimba Announces New “Blue and Improved” Original Line® Cylinders

Bimba Manufacturing Company, a provider of pneumatic, hydraulic, and electric solutions, announced a series of product enhancements to its indus-try-leading round line, non-repairable Original Line® product series.

These changes include design modifications to further extend the catalog life rating of the cylinders from 1,400 miles to 3,000+ miles, as well as new product labeling and packaging.

“These design enhancements are the culmination of more than three years of product testing and communications with our customers. It will more than double the life of our Original Line®, enhancing the value to our customers of the industry’s hardest working, longest lasting cylinder,” said Jerry Scherz-inger, Bimba’s OL Product Marketing Manager. “Additionally, we are updat-ing the look of the cylinder by replacing our pre-existing red logo with an updated blue logo, as well as introducing new packaging that will be easier for customers to remove prior to installing our cylinders.

Scott Meldeau, Bimba’s Vice President of Sales and Marketing said, “These changes reflect the aggressive corporate approach Bimba is taking to strengthen our existing products, in addition to developing new products to position us for future growth.”

To learn more, visit www.bimba.com.

Contact:Telephone: 708-534-8544

or 800-44-BIMBA

Fax: 708-235-2014

[email protected]

www.bimba.com


134 October 2014 | Food Engineering | www.foodengineeringmag.com


ADVERTISEMENT

For more information call 316-284-2020, email [email protected]

or visit our website at www.buntingmagnetics.com.


For over 50 years, Bunting® has established itself as an industry-leading

manufacturer in several product lines. Since our founding, we have been

solving problems with magnetic energy

for manufacturers of everything from

paper towels and cardboard boxes to

automobiles, plastic housewares, food

products, and electronic equipment.

At this years Process Expo show we

will be featuring equipment from our

metal detection and magnetic separation

lines. Our meTRON 07 CI metal

detector has the latest in electronics,

aptly named, imagePHASE and is the

newest product recognition software

in the world. imagePHASE allows for

greater sensitivities and fewer false rejects. This combined with our DCM

washdown conveyor ensures your product will be free from contamination

as it moves down the line.

From our magnetic separation equipment we will feature our popular

Center-Flow magnet (CFM). Our CFM has been redesigned for easy and

quick cleaning capability. Bunting Center-Flow Magnets are designed to

handle materials that are non-abrasive or not subject to damage by impact.

It can be installed easily in any position or angle with factory supplied

compression couplings. This product is ideal for use in dilute-phase

pneumatic conveyor systems.

BuntingBimba

Bimba Announces New “Blue and Improved” Original Line® Cylinders

Bimba Manufacturing Company, a provider of pneumatic, hydraulic, and electric solutions, announced a series of product enhancements to its indus-try-leading round line, non-repairable Original Line® product series.

These changes include design modifications to further extend the catalog life rating of the cylinders from 1,400 miles to 3,000+ miles, as well as new product labeling and packaging.

“These design enhancements are the culmination of more than three years of product testing and communications with our customers. It will more than double the life of our Original Line®, enhancing the value to our customers of the industry’s hardest working, longest lasting cylinder,” said Jerry Scherz-inger, Bimba’s OL Product Marketing Manager. “Additionally, we are updat-ing the look of the cylinder by replacing our pre-existing red logo with an updated blue logo, as well as introducing new packaging that will be easier for customers to remove prior to installing our cylinders.

Scott Meldeau, Bimba’s Vice President of Sales and Marketing said, “These changes reflect the aggressive corporate approach Bimba is taking to strengthen our existing products, in addition to developing new products to position us for future growth.”

To learn more, visit www.bimba.com.


or 800-44-BIMBA

Fax: 708-235-2014

[email protected]

www.bimba.com



or 800-44-BIMBA

Fax: 708-235-2014

[email protected]

www.bimba.com

See us at PACK EXPO booth # S-6133




Stainless Steel PlatformsElevate your operations with a Cubic Designs pre-manufactured stainless steel platform. These systems are custom designed by on-staff engineers to meet your exact facility needs.

• Stainless and carbon steel designs• Bead blast and powder coat finishes• Can meet USDA/FDA requirements• Professionally-Engineered for any

seismic zone• Quick, easy installation with little

plant disruption

Looking for an attractive, sanitary solution to increase your footprint? Call Cubic Designs today.

800.826.7061 www.cubicdesigns.com

© 2015 Cubic Designs

ON THE RISEON THE RISEON THE RISEON THE RISE

the perfect fitVISIT US AT PACK EXPO. BOOTH #7933VISIT US AT PACK EXPO.BOOTH #7933

Expertly Engineered for Precision, Power and Performance

The new Stainless Right Angle Drive from Cone Drive is expertly engineered

to withstand the harsh cleaning processes required in sterile manufacturing

environments. Featuring a smooth, stainless steel housing that is easily

cleaned to ensure bacteria-free surfaces, the Stainless Right Angle Drive is

NSF and A3 certified and is the industry’s only IP69K tested and rated worm

gear assembly.

The Cone Drive Difference

Cone Drive® is the industry leader in precision motion control and power

transmission solutions, delivering the highest level of accuracy, torque

and shock load capacity in the smallest amount of space. Renowned

for precision, quality, durability and consistency, Cone Drive specializes

in designing modified and custom solutions across multiple industrial

applications around the globe.

Contact: Cone Drive

240 E. 12th Street

Traverse City, MI 49684

888-994-2663

+1 231-843-3393

www.conedrive.com

See us at PACK EXPO Booth # S-6315


• NSF and A3 certified

• 5-Year warranty

• Patented non-fretting blue bushing prevents micro-welding

• Stainless finish withstands harsh cleaning practices

• Smooth housing eliminates bacteria growth

• Made in the U.S.A.

Cone Drive




Douglas Machines Corp. offers a full line

of automated washing and sanitizing

equipment for all containers commonly

used in the food processing and distribu-

tion industries. Batch and continuous

cleaning designs are available for several

hundred to several thousand containers

per hour. This year’s booth features some

of their most popular models: a Rack

Washer for detachable weigh scale parts,

a Tunnel Washer for shipping containers,

a Belt Washer for spiral conveyors, a Bar-

rel/Drum Washer and Bucket and Utensil

Washer. Other models are available for

baking pans, trays, baskets, moulds,

pallets, lugs, totes, vats, bins, screens,

smoke sticks and smoke racks .

Call 800-331-6870, or visit www.dougmac.com to get additional information

on a model suited to your specific needs.

Douglas Machines Corp.

Contact: 2101 Calumet Street, Clearwater, Florida 33765

Phone: 727-461-3477 or 800-331-6870

Fax: 727-449-0029

Web Site: www.dougmac.com



ADVERTISEMENT

Douglas Machines Corp. offers

a full line of automated washing

and sanitizing equipment

for all containers commonly

used in food processing and

distribution industries. Over

80 standard models exist to

quickly and efficiently clean

pans, trays, moulds, scale parts,

screens, pallets, lugs, totes,

racks, smoke trucks, bins, vats,

barrels and buckets. Batch and

continuous cleaning systems

are available to clean several

hundred to several thousand

containers an hour.

Each model is designed to

save labor, water, chemical

and energy, plus help you

consistently meet today’s

high standard if cleanliness

and sanitation. Ensure an

effective Food Safety Program

with Douglas Washing and

Sanitizing Systems. For a

complete overview or for

literature and specifications on

a particular model, visit

www.dougmac.com or call

800-331-6870 today.

Douglas Machines Corp.

Contact:Douglas Machines Corp.

2101 Calumet Street, Clearwater, Florida 33765

Phone: 727-461-3477 or 800-331-6870 (U.S. and Canada)


Web Site: www.dougmac.com

See us at PACK EXPO International booth # E-7324

This year at PACK EXPO International Dorner will be displaying some of

the newest conveyor technologies including the 3200 Series Modular Belt

Conveyor, the AquaGard® 7100 Series and the 2200 Series SmartFlex®

Conveyor.

Dorner’s new 3200 Series Modular

Belt Conveyor is ideal for part

handling, accumulation, positioning,

high speeds, long runs, and product

transfers. Designed with ease

of integration in mind, the 3200

Modular Belt conveyor features

innovative transfer options as well as

complete flexibility in layout including multiple curves, inclines and declines.

The AquaGard® 7100 Series Stainless

Steel Flexible Chain Conveyor can twist

and turn into the tightest of spaces.

It is ideal for product routing in wipe

down sanitary applications in the

food, packaging and pharmaceutical

industries. As the footprint in

production areas and plants continues to shrink, the 7100 Series Conveyor

is the ideal platform to maximize available space.

Dorner’s SmartFlex® 2200 Series

flexible conveyor is a high-

performance, modular table-top

chain conveyor that is simple

to configure and even simplifier

to acquire. It’s ideal for part

handling, tight spaces, buffering,

accumulation, and elevation

changes. And with Dorner’s industry leading delivery time, the conveyor can

be shipped pre-assembled in only 5 working days.

Contact:Dorner Mfg. Corp

975 Cottonwood Ave

P.O. Box 20

Hartland, WI 53029

Tel: 800.397.8664

Fax: 800.369.2440

[email protected]

www.DornerConveyors.com/FEM

Dorner

125www.foodengineeringmag.com | Food Engineering | June 2014

2014 | CORPORATE PROFILES

Dorner Mfg. Corp.Founded in 1969 and based in Hartland, Wisconsin, Dorner Mfg. Corp is a privately held World Leader in the design, applications, manufacturing, and integration of conveyor systems. Companies from over 1,200 different industries worldwide turn to Dorner to achieve improved efficiency, productivity, and a positive ROI.

Dorner conveyor systems are flexible, easy to select and easy to integrate. Dorner’s line of stainless steel, food handling conveyors are designed for fast and effective sanitation. They are ideal for environments that require anything from wipe down cleanings to daily high-pressure wash-downs with caustic cleaners.

D o r n e r ’ s A q u a G a rd ® conveyors offer maximum layout flexibility for a wide va r ie ty o f packag ing applications. They also provide the industry’s best transfers which reduces product loss. The AquaPruf® line of

hygienic designed wash-down conveyors allows for sanitation in systems that carry everything from ready-to-eat foods to protein. AquaPruf® is designed to provide access to the internal frame in seconds and can be disassembled in less than five minutes, reducing change over and sanitation down time.

Both styles are constructed with a stainless steel, open frame design with minimal horizontal surfaces, and are available with flat belt or plastic chain. They are available in a variety of configurations, such as straights, curves, inclines, declines, and z-frames. All delivered in an industry leading 7 to 10 days.

Safety

innovative technology

provides the ozone to

DEL‘s Food designed integrate

production and DEL’s

Sanitation supplement,

traditional techniques

sanitation life and

Ozone comprehensive

complement to methods

quality Every food

benefit from USDA,

approved existing

system you reduce

foodborne effectiveness, DEL

green and

Contact:Dorner Mfg. Corp

975 Cottonwood Ave

P.O. Box 20

Hartland, WI 53029

Tel: 800.397.8664

Fax: 800.369.2440

[email protected]

www.DornerConveyors.com/FEMSee us at PACK EXPO Booth # C-1847




Flexicon Corporation

Handle virtually any bulk food product

Flexicon stand-alone equipment and automated plant-wide systems convey,

discharge, condition, fill, dump

and/or weigh batch bulk foods

dust-free

Flexicon Corporation

engineers and manufactures a

broad variety of equipment that

handles virtually any bulk food

material, from large pellets to

sub-micron powders, including

free-flowing and non-free-

flowing products that pack,

cake, plug, smear, fluidize, or

separate.

The line includes: Flexible Screw Conveyors, Tubular Cable

Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag

Conditioners, Bulk Bag Fillers, Pallet Dispensers, Bag Dump Stations, Bag

Compactors, Drum/Box/Container Dumpers, Weigh Batching and Blending

Systems, and Automated Plant-Wide Bulk Handling Systems—all to food,

pharmaceutical or industrial standards.

Ideal for fragile bulk food products is the company’s Flexi-Disc®

Tubular Cable Conveyor, shown at left.

Custom engineered systems incorporate equipment manufactured

by Flexicon as well as packaging machines, blenders, weigh feeders, screeners

and any other process and storage equipment required�all integrated with your

process and guaranteed to perform.

Large-scale bulk handling systems are managed by Flexicon’s Project

Engineering Division that offers dedicated Project Managers as your single point-

of-contact, Engineering Teams that ensure

smooth integration with new or existing systems,

and the resources and effectiveness only a major

bulk equipment manufacturer can provide.

Flexicon’s worldwide testing facilities simulate

full-size customer equipment and validate

system performance.

The company has recently doubled the

size of its manufacturing facility and world

headquarters located in Bethlehem, PA, and also

operates manufacturing facilities in Kent, United

Kingdom; QLD, Australia; and Port Elizabeth,

South Africa.

Contact:Flexicon Corporation2400 Emrick Blvd.Bethlehem, PA 18020-8006Phone: 888 353 9426Fax: 610 814 [email protected]

Flexicon offers stand-alone bulk handling equipment as well as plant-wide systems integrated with new or existing processes

New Flexi-Disc® Tubular Cable Conveyor for friable bulk foods is available integrated with upstream and downstream equipment

Contact: Eriez

2200 Asbury Road

Erie, PA 16506

814-835-6000

www.purity.eriez.com

See us at PACK EXPO # S-5901

Eriez is the #1 name in Magnetic Separators, and continues to out

perform all other magnets on the market today. Be sure to visit our booth

to see latest advancements in magnetic strength… including head-to-head

comparisons!

Rare Earth Magnetic SeparatorsIn order to continually improve separation quality, Eriez has designed a new

permanent Rare Earth magnetic separator capable of extracting the very

smallest of ferrous objects and

even work-hardened stainless steel

from product flows. Eriez employed

sophisticated finite element analysis

to produce this incredibly powerful

magnetic circuit intended for

applications demanding the highest

levels of product purity.

Eriez will display these magnetic separators in tube, grate, liquid-line trap and

a wide variety of self-cleaning designs.

Xtreme Metal Detectors Combine the Xtreme’s

benchmark-setting

sensitivities with its

feature packed controls

in a high-pressure

wash down aperture

head... all at an xtremely

attractive price, and

you’ve got the best

dollar-for-dollar value

on the market today.

Now Xtreme is available with an optional “Enhanced Platform” using

advanced technology to detect metals in the most challenging

applications. EP has shown significantly improved sensitivities in a range of

dairy, cheese, meat and even rubber products. Stop by the Eriez booth to

see if EP is right for you.

Eriez offers the Xtreme in tunnel, tunnel conveyor, vertical and liquid-line

models with a wide range of reject options.

Eriez




Introducing the Interceptor Metal DetectorPresident, Steve Gidman will be in

attendance at Pack Expo to introduce

and demonstrate the impressive

effectiveness of their New Interceptor

Metal Detector.

At a much lower cost of ownership

than x-ray systems, this new

simultaneous multi-frequency

technology provides food producers,

especially those with difficult

applications, a cost effective alternative for their food safety programs. Steve

will be speaking about the Interceptor at an Innovation Stage on Monday

September 28th at 3:00pm.

Never Obsolete: Fortress Metal Detectors Are Always Supported On display at Pack Expo, will be several models from their range of

sustainable metal detectors. Fortress metal detectors have always been

engineered with a Never Obsolete Commitment. Their customers have

peace of mind that a Fortress metal detector will always be supported

with parts, software upgrades and a global service team for the life of the

detector. Stay up to date without having to purchase a new detector.

Optimized Metal Detection Fortress Technology is the only North American Metal Detection

Manufacturer that, since its inception in 1996, custom manufactures their

equipment to suit their customers’ needs, application and specifications to

ensure optimal metal detection, without an exorbitant price tag.

Fortress Technology

Contact:Fortress Technology Inc.

1-888-220-8737 or 416-754-2898

[email protected]

www.fortresstechnology.com

See us at PACK EXPO Booth #C-2430

Fristam Pumps

Contact:Fristam Pumps USA

2410 Parview Road

Middleton, WI 53562

800-841-5001

www.fristam.com/usa

See us at PACK EXPO Booth #7508 South Upper

Fristam is a leading global

manufacturer of high-

performance stainless steel

pumps, blenders, and mixers.

Our equipment is designed

for precision and durability

to outlast and outperform all

others and provide the highest

lifetime value.

Powder MixersFristam’s Powder Mixer blends

dry and wet ingredients into

a fluid stream. The Fristam

Powder Mixer provides consistent batch-to-batch repeatability and

reduced blend times. Powder induction rates up to 600 lbs/min.

Shear BlendersFS Shear Blenders improve product consistency by removing agglomerates

and preventing lumps and masses in product. It produces repeatable

results and reduces raw material usage and processing times.

Positive Displacement PumpsFristam positive displacement pumps provide gentle product handling,

easy maintenance and hassle-free operation. Our heavy-duty FKL series is

built for no-disassembly, rotors-in

“True CIP”. Its balanced rotors

and large-diameter shafts make it

durable and reliable. In addition,

we manufacture standard-

duty and dual-duty PD pumps

(transfer and CIP in one pump).

Centrifugal PumpsFristam centrifugal pumps serve as

the industry benchmark for quiet, efficient, low-maintenance operations.

Our line includes standard-duty, heavy-duty, front-loading seal and self

priming centrifugal pumps.




GEA provides innovative

solutions for preparing,

further processing,

preserving, chilling,

packaging and freezing

a wide variety of meat,

poultry, fish, seafood, fruit,

vegetables, dairy products,

bread, confectionary and

food ingredients.

From standard plant systems

to customized solutions,

all GEA food technology is

designed to meet optimum

hygiene and quality

standards, while operating

efficiently and sustainably.

Our technical expertise is

complemented by project

management, planning and

cost control services to

help our customers achieve

flexible and cost-effective

food production.

GEA has a wide-

ranging portfolio that

spans almost the entire

food chain around 70%

of the products sold

in supermarkets have

been in contact with our

technology.

Contact info:GEA Group, 9165 Rumsey Road, Columbia MD, 21045

410-997-8700

[email protected]

www.gea.com

See us at PACK EXPO Booth # C-5000 & C-5200

GEA Group

Heat and Control is a single-source global manufacturer and supplier

of equipment for weighing, conveying, tray sealing, packaging, snack

bagmaking, metal detection, X-ray inspection, checkweighing, food

processing and cooking, seasoning and coating application. With our

partners Ishida, CEIA, and Spray Dynamics, we can provide one machine or

the complete line. We stand behind you with the industry’s best pre- and

post-sale technical support, including applications assistance, engineering,

installation, parts, service, and training. Visit one of our demonstration centers

where you can test your products on some of our latest equipment. Contact

Heat and Control today for full-service assistance with your next project.

Let’s Talk Solutions at Pack Expo Las Vegas!

Heat and Control, Inc.

Contact:Heat and Control, Inc.

Phone: 800 227 5980 / 510 259 0500

Fax: 510 259 0600


www.heatandcontrol.com

See us at PACK EXPO Booth # C-3627




Company DescriptionIMA Dairy & Food USA’s equipment portfolio covers nearly all areas of

packaging machine applications. The company provides filling and sealing

machines (FS) for preformed cups and bottles, and forming, filling and

sealing machines (FFS) for packaging products in the food, dairy and

beverage segments (aseptic filling available), as well as wrapping machines

for packaging butter, margarine, etc.

IMA Dairy & Food

USA also offers

aseptic vertical form,

fill and seal machines

for stick packs/

pouches, as well as

FS and FFS machines

for packaging single

portions of coffee,

honey, jam, etc.

Recent Developments• IMA has introduced the Hassia FFS Machine P300, a form-fill-seal

platform for the production of portion packs. Ideal for manufacturing

and filling small to medium-sized cups, the P300 FFS Machine produces

up to 63,000 portion cups/hr and comes equipped with an integrated

case packing system. The P300 is the first in a new line of cost-effective

FFS machines combining compactness and low operational and repair

costs with high availability and more than 1,000 types of cup sizes and

configurations, including oval, round, square and honeycomb.

• IMA’s Erca EF Series of Form-Fill-Seal Machines allow food

manufacturers to create proprietary shapes for cups and bottles at nearly

the same cost as standard molds. Known as Open Mold, the system

can shape unique-to-brand containers for food products including

yogurt, cream spreads, jellies/jams, juices, water, butter, margarine,

sauces and fruit salads. On EF FFS Series machines, manufacturers

utilizing Open Mold can produce up to 18,000 product-filled portion

cups, or 16,800 product-filled bottles, per hour.

Contact:IMA Dairy & Food USA

523 Raritan Center Parkway

Raritan Center Edison, NJ 08837 / USA

Tel: +1 732 343 7600


Website: www.imadairyfood.com

IMA Dairy & Food USAIFS is a globally recognized leader in developing and delivering enterprise

software for enterprise resource planning (ERP), enterprise asset

management (EAM) and enterprise service management (ESM). IFS brings

customers in targeted sectors closer to their business, helps them be more

agile and enables them to profit from change.

IFS Applications is a pioneer in providing business software based on

actual business processes. Companies can reconfigure the software on

the fly, enabling them to adapt quickly to changing market conditions.

And because IFS Applications is component-based, customers need only

deploy the functionality they require and implement it step by step, adding

new components as their business changes or expands. IFS Applications is

based on an open design using industry standards, so integration with other

enterprise software is simple and seamless, eliminating technology lock-in.

IFS Applications puts the user back in the driver’s seat by offering an

interface that can be adapted to individual needs. With Google-like search

functionality and no-nonsense navigation, it leads to increased productivity

and efficiency—and a healthier bottom line.

IFS is a public company (XSTO: IFS) founded in 1983 and currently has over

2,700 employees. IFS supports more than 2,400 customers worldwide from

its network of local offices and through a growing ecosystem of partners.

For more information visit: www.ifsworld.com.

Contact:Laura Stockhausen

Address: 300 Park Boulevard, Ste 555,

Itasca, IL 60143

Phone: 888-437-4968


URL: www.ifsworld.com


IFS North America




Managing Compressed Air Contamination Risk

With growing concerns over food safety, it’s critical to have a compressed air

partner you can depend on for a full range of solutions that deliver cost and

energy savings without sacrificing quality. For more than 140 years, Ingersoll

Rand has remained passionate about the reliability and efficiency of the

solutions we provide, including:

· Oil-Free and Oil-Injected Air Compressor Systems

· Dryers, Filters, Lubricants

· Controls & Automation

· Air Audits & Leak Assessments

· Rentals & Remanufacturing

· Maintenance & Risk Transfer Agreements

We’ll help you assess the risk of contamination, determine air quality

standards to support your HACCP, and choose the appropriate equipment

for your individual processing and packaging applications. For every air

need, you can depend on our solutions to help avoid compressed air

contamination—so you can Stress Elsewhere.

Contact: Ingersoll Rand

800-D Beaty Street

Davidson, NC 28036

(800) 483-4981

IngersollRand.com/StressElsewhere

Ingersoll RandPeco Controls Corporation and InspX Corporation are leading providers

of advanced technology inspection solutions for the food and beverage

industries. With headquarters in Fremont, CA, the company serves

customers around the world and inspects over 1 Billion food and beverage

containers daily. The company specializes in accurate high speed package

inspection in machines that are easy to use with a low cost of ownership.

At Peco InspX

we’re obsessive

at ensuring that

we deliver a high

quality machine

that is seamlessly

integrated into your

operation. Our

applications experts

work closely with you to make our equipment more productive and efficient

so your operations can be more profitable.

Our allegiance to customer service goes beyond traditional post-sale

service. At Peco InspX we partner with our customers in ways that facilitate

their success. Using our extensive applications engineering expertise,

we seek to design the best possible inspection equipment to exceed

our customer’s requirements. With Real-Time Machine Monitoring and

Remote Support over 95% of customer issues are resolved remotely. We

demonstrate our commitment in serving customers large and small whose

facilities span 6 continents.

Contact:[email protected]

Phone number: (510) 226-6686


Peco InspX




Intralox, L.L.C. is a global provider of conveying solutions, offering direct service in more than 40 countries. We specialize in three innovative technology platforms: Activated Roller Belt™ (ARB™) equipment, ThermoDrive Belting, and Modular Plastic Conveyor Belting, which includes our DirectDrive spiral system. With the strongest guarantees for belt performance and on-time shipping and significant expertise in the industries we serve, Intralox has become a world leader by consistently delivering where it matters most.

Over the last four decades, Intralox has developed a worldwide reputation for ethical and responsible business practices, and maintained our founder’s commitment to treating employees, customers, and suppliers with honesty, fairness, and respect. Our growth and sustained success is the result of a diligent focus on continuous improvement, a core belief that self-managed people are our greatest asset, and a commitment to ideas, teamwork, and effort.

The Intralox Strategy integrates premium products with a powerful blend of engineering expertise, services, global support and delivery, all backed by the strongest, written performance and delivery guarantees, for the pursuit of continuous, long-term profitability for our customers.

Intralox, L.L.C.

Contact:Intralox, L.L.C.

301 Plantation Road, Harahan, LA

1 800 535 8848

[email protected]

See us at PACK EXPO Booth: C-3336

Paxton Products manufactures

high efficiency centrifugal blowers

and custom-engineered air

delivery devices, used for drying,

blow off, and air rinsing of food

and beverage products during

processing or packaging.

Centrifugal Blowers by Paxton Products are highly efficient, providing

150 – 1150 cfm of air at pressures of 30 – 100 inches of water. Available in

sizes from 3 – 20 hp, all Paxton blowers carry a full three year warranty.

Air Delivery Devices are custom-

engineered to maximize drying and blow

off of products or surfaces. From an air

knife design to manifolds to halos that

encircle the product to individual nozzles,

we’ll configure what’s needed for your

application.

PowerDry System is a pre-configured drying system, originally designed

for date coding applications, and now setting the standard for a complete

Air System that can be used for drying and blow off for a wide variety of

cans, bottles and jars.

Ionized Air System dissipates the

static that causes particulates, dust and

contaminants to adhere to products

and surfaces, then uses high velocity air

from Paxton’s high efficiency blowers

and air delivery system to remove the

contaminants. The Ionized Air System is

used in a wide variety of applications:

• Bottle Rinsing for glass or PET bottles and jars, high speed and low

speed lines, including the hard to clean narrow mouth 2 liter PET bottle

• Can Rinsing, for both high and low speed lines

• Cleaning of the outside of bottles or packages after packaging of

powdery or dusty materials

Paxton Products

Contact:Rick Immell, International Sales Manager

Paxton Products, an ITW Company

10125 Carver Road, Cincinnati, OH 45242

800-441-7475

[email protected]

www.paxtonproducts.com





We specialize in custom vision-

guided robotic solutions for

high sanitary food packaging

environments. Our history,

experience and application

knowledge is the backbone

of our Design for Agility®

philosophy, which focuses on

offering simple, user-friendly

solutions to complex packaging challenges.

Our robotic solutions include:

• Osprey Case Packers & Chub Loading Systems• Talon Pick & Place Systems • Heron Tray Loaders

Benefits of our robotic primary and secondary packaging solutions:

• Flexible Design with Small Footprint can easily integrate into existing

lines

• Rapid Changeover with few adjustments and no “tweaking”

• USDA-Approved design for sanitary, wash-down environments

• Patented and Proprietary End-Of-Arm Tooling designed to handle:

• Meat, poultry and dairy products

• Frozen and prepared foods

• Bakery products such as tortillas, flat bread, snack cakes

• High reliability provided by ABB IRB 360 FlexPicker

Our PIVT™ (Package Integrity Validation Technologies) System

is a collection of technologies that

utilizes vacuum, vision and other

sensor technologies to detect seal

contamination, leaks and pinholes that

lead to the loss of package integrity.

PIVT™ can detect leaks at high

speeds and is ideal for packages that contain a brine or juice such as hot

dogs, sliced luncheon meats, and sausages. This enabling technology allows

a robot to identify a leaky package, at line speeds of up to 160 packages/

min, and reject it.

We’re active members of PMMI, FPSA, BEMA and the Wisconsin Cheese

Makers Association as well as a long time Strategic Partner for ABB Robotics.

JLS Automation

Contact:Craig A. Souser – President / CEO

3495 Industrial Blvd, York, PA 17402

717-505-3800

[email protected]

Www.jlsautomation.com

See us at PACK EXPO Our booth number is C-4703

Key Technology offers food processors the single most complete source

of high performance digital sorting, conveying, and process automation

systems.

Laser / camera sorting systems remove defects and foreign material (FM) to

improve product quality, optimize yield, reduce labor, and improve process

control to enhance plant efficiencies.

These sorters are complemented by Key’s other processing systems – Iso-

Flo® vibratory conveyors; Horizon™ horizontal motion conveyors; Impulse®

electromagnetic conveyors; equipment for sizing, grading, and separating;

systems for blanching, air cooling, air cleaning, washing, and feeding.

Key’s global support includes application testing, line integration, installation

and start-up, training, customizable service packages for maintenance and

repairs, and more.

173www.foodengineeringmag.com | Food Engineering | January 2015

SPECIAL ADVERTISING SUPPLEMENT

PACK EXPO SHOW PORTRAITS INT’L PRODUCTION AND PROCESSING EXPO SHOW PREVIEWS


PROFILES

Kagetec

Contact:24631 Saint Benedict Rd

Jordan, MN 55352

m: 612.298.8838

p: 612.435.7642

f: 612.435.7643

e: [email protected]

w: www.kagetecusa.com

Kagetec provides chemical resistant, hygienic, industrial flooring systems,

consisting of slip resistant ceramic tile and integrated stainless steel drains.

We have specialized in the installation of flooring in wet process areas for

thirty years, and offer a ten year warranty.

Kagetec floors are unsurpassed in their sanitary/safety qualities, and

mechanical/thermal/chemical loading capabilities.

Kagetec takes pride in maintaining the highest quality floors by performing

the installations ourselves. Our employee craftsmen install over 1 million

square feet of floor tile annually worldwide.

Kagetec offers several flooring solutions depending on your project require-

ments. The Kagetec BS (basic system) has been used since our inception to

provide a chemical resistant floor that withstands the daily rigors of industrial

use, and is still widely used today.

Are you repurposing a warehouse into wet production? The Kagetec GFK

system creates a sloped mortar bed, minimizing the amount of concrete to be

removed. Is installation time a critical factor? The Kagetec AR system provides

the fastest installation/cure time. Kagetec also installs static dissipative floors for

sensitive production areas, our AS (anti-static) system eliminates static buildup.

Our line of customizable trench and area drains are available in 304 and 316

stainless steel. Kagetec offers heavy duty sanitary drains that incorporate

double box tubing reinforcement in our trench design and fully welded

bar grate covers. The sizes and design are custom tailored to your specific

water volumes and product use. Our craftsmen typically install the drains to

ensure proper elevation and orientation. Of course, all our drains can also be

installed by your plumber in non-tiled areas as well.

Safety - The Kagetec vitrified tile incorporates a slip resistant surface into its

design that is matched to the production area it is being used in. This helps

to significantly reduce slip and fall accidents while maintaining the highest

level of cleanability. Unlike other products, the slip resistant surface of the

tile does not wear off or become dislodged over time creating harbors for

bacterial growth.

In addition to our quality control plan, Kagetec has a full written safety plan

in place for our staff. Jobsite safety is first priority on our projects.

If you are dissatisfied with the quality of your flooring, and would like to have

a product that does not require frequent renewal or replacement. Kagetec

would like to talk to you. We would like to know what floor systems you nor-

mally use, and if Kagetec can offer a better solution for your facility.

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11/26/14 10:08 AM

106 July 2014 | Food Engineering | www.foodengineeringmag.com

2014 | CORPORATE PROFILES

Key TechnologyKey Technology offers food processors the single most complete source of high performance digital sorting, conveying, and process automation systems from a single supplier.

Laser / camera sorting systems, Cayman®, Manta®, Optyx®, Python, Spyder®, Taurys™, and Tegra® remove defects and foreign material (FM) to improve product quality, optimize yield, reduce labor and improve process control to enhance plant efficiencies.

These sorters are complemented by Key’s other processing systems – Iso-Flo® vibratory conveyors; Horizon™ horizontal motion conveyors; Impulse® electromagnetic conveyors; equipment for sizing, grading, and separating; systems for blanching, air cooling, air cleaning, washing, and feeding.

Key’s global support includes application testing, line integration, installation and start-up, training, customizable service packages for maintenance and repairs, and more.

Contact:Key Technology, Inc.


Tel: 509 529 2161

www.key.net

Millard

Millard Manufacturingsanitary machinerydesign, buildpans to sanitaryfloor with

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Key Technology

Contact:Key Technology, Inc.


Tel: 509 529 2161

www.key.net

See us at PACK EXPO Las Vegas booth #S-7222




METTLER TOLEDO

Trust the Product Inspection Industry Leaders

Offering a full line of innovative product inspection and connectivity

solutions, METTLER TOLEDO helps manufacturers ensure product quality,

increase productivity, and protect their customers and brand.

METTLER TOLEDO will showcase a variety of metal detectors,

checkweighers, vision and x-ray inspection systems, and track and trace

equipment designed for all types of food and pharmaceutical applications.

From economical systems to sophisticated, state-of-the-art systems with

customized material handling solutions, our systems can ensure perfect

product presentation, mark and verify packages and label integrity, ensure

weight range compliance, detect physi cal contaminants and inspect

contents inside the closed package

Our inspection systems are offered with a variety of interfaces including

Ethernet TCP/IP, EtherNet/IP, Modbus TCP, USB, Serial, and our ProdX

software for a complete “off the shelf” solution. OMAC compliant PackML

data is displayed locally and available over a variety of interfaces. We will

demonstrate real-time data collection and monitoring of all of the equipment

in both booths.

All systems are supported with comprehensive engineering solutions,

product testing, training, and 24/7 customer support with nationwide field

service.

Contact:METTLER TOLEDO

6005 Benjamin Road

Tampa FL 33634

(813) 889-9500

FAX: (813) 881-0840

www.mt.com/pi

[email protected]

See us at PACK EXPO Booth #C1814 and #N607

Lubriplate Lubricants Company

Lubriplate offers a complete line of high-performance, NSF H-1 Registered, Food Machinery Grade Lubricants. Manufactured under strict NSF/ ISO 21469 Certified and ISO 9001 Registered quality control standards, these lubricants are formulated to deliver a number of significant, cost effective advantages, including; extended lube and fluid change intervals, multiple application capability, lubricant inventory consolidation and improved performance.

All Lubriplate H-1 Lubricants are manufactured with ingredients that comply with FDA regulation 21 CFR 178.3570 for lubricants with incidental food contact. They meet USDA H-1 safety standards and are authorized for use in federally inspected meat and poultry plants. Clean, safe and non-toxic, their use can eliminate lubrication as a critical control point in HACCP programs.

All Lubriplate Lubricants come with the exclusive Lubriplate ESP Extra Services Package at no-charge. Services include; a complimentary plant lubrication survey by a factory direct representative, lubrication scheduling software, color coded machinery lubrication tags and follow-up lubricant analysis.

Contact:Lubriplate Lubricants Company

Newark, NJ 07105 / Toledo, OH 43605

Phone: 800-733-4755


www.lubriplate.com





For over half a century Meyer has been one of the leading innovators

of bulk material handling and food processing equipment. As one of the

most respected names in the industry, Meyer prides itself on being a

totally integrated manufacturer offering standardized equipment as well as

complete custom distribution systems. The company has a full engineering

staff with decades of experience capable of taking a project from initial

concept through installation.

• Vibratory Conveyors

• Bucket Elevators

• Belt Conveyors

• Hopper-Feeders

• Mix-Blend Systems

• Distribution Systems

• Vibratory Feeders

• Continuous Weighing Conveyors

• Integrated Systems

• Washers

• Blanchers

• Chillers

Recognizing our customers specific requirements and providing a

customized solution is what makes Meyer stand out above the rest.

Contact: Meyer Industries, Inc.

San Antonio, TX

(210) 736-1811

[email protected]

www.meyerindustries.com


MEYER INDUSTRIES, INC. Mitsubishi ElectricMitsubishi Electric Automation,

among the top three automation

suppliers globally, offers

American manufacturers, system

integrators, and OEMs the most

advanced and reliable factory

automation solutions for improving

performance, enhancing quality,

and furthering competitiveness.

Mitsubishi Electric Automation is a major global manufacturer as well as

an automation systems supplier. Mitsubishi Electric Automation faces

all the same issues of performance, cost, and quality as its customers.

Because they are living the reality of manufacturing every day, the people

at Mitsubishi Electric Automation understand the energy, performance, and

sustainability trends that are shaping manufacturing for decades to come.

Mitsubishi Electric Automation is known for its leadership in motion

control/servo solutions as well as integrated control platforms. In terms of

components, the company is recognized for the innovation, reliability, and

performance of its programmable logic controllers, human machine interface

devices, variable frequency drives, computer numerical controls, and robots.

Mitsubishi Electric Automation customers know that the company is

dedicated to their success because of the superior technical and logistical

support they receive. Every North American manufacturer, system integrator,

and OEM looking for a solution for improving performance and reliability

while lowering total cost of ownership will benefit from a supplier/customer

relationship with Mitsubishi Electric Automation. Mitsubishi Electric

Automation U.S. operations are headquartered in Vernon Hills, Illinois —

30 minutes from O’Hare International Airport. The company’s website is

us.mitsubishielectric.com/fa/en.

Contact: Mitsubishi Electric Automation, Inc.

500 Corporate Woods Pkwy

Vernon Hills, IL - 60061 - US

Tel: (847) 478-2100

us.mitsubishielectric.com/fa/en/





Contact:Nercon

600 S. Commercial St.

Neenah, WI 54956

[email protected] us at PACK EXPO Booth # C-4200

October 2014 | Food Engineering | www.foodengineeringmag.com


ADVERTISEMENT

Nercon

Contact:Nercon

600 S. Commercial St.

Neenah, WI 54956

[email protected]

[email protected]


Nercon’s Rapid-Rail™ Puts Packaging on the Fast Track

Neenah, WI – Nercon’s new patent-pending Rapid-Rail™ will be introduced at the Pack Expo Show in November – Booth #N5345. Engineered to simplify changeovers on the packaging line, Rapid-Rail offers a single point, easy-to-use hand adjustment of guide rails to accommodate multiple package sizes on the same piece of equipment. Now several points along the conveyor, over a long distance, can be controlled from one location on the line.

The value to packaging customers is multi-fold. Time savings with Nercon’s Rapid-Rail is HUGE! On a long carton conveyor line with numerous guard rail brackets, it could take several hours for rail adjustments to changeover to different size cartons. With Rapid-Rail, all adjustments are made from only a few locations and affect all points along the line. Change from 32 oz. bottles to 16 oz. bottles in a minute with Rapid-Rail. The equipment works equally well with any type of grocery packaged product.

Nercon employs a simplified, more economical design on Rapid-Rail that limits the number of moving parts. With a repeatable system, it’s easy to fine-tune the path as products go through the turn. The new design also enables operators to add a motor and control any adjustments right from a conventional control system.

To learn more, visit Nercon at Booth #N5345 at Pack Expo or call (844)293-2814. www.nercon.com

METTLER TOLEDO

Contact:METTLER TOLEDO

Benjamin Road

Tampa, FL 33634

813-889-9500

[email protected]

www.mt.com/pi

us at PACK EXPO International booth # 1706 & 776

METTLER TOLEDO is your single source for product inspection and con-

nectivity solutions. As the world’s largest manufacturer of metal detectors,

inspection systems, checkweighers, and machine vision systems, we

a solution for virtually every application. From economical systems to

sophisticated, state-of-the-art systems with customized material handling

solutions, our systems can ensure perfect product presentation, verify

package and label integrity, ensure weight range compliance, detect physi-

contaminants and inspect contents inside the closed package.

Safeline Metal DetectionMETTLER 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

Safeline X-ray InspectionMETTLER TOLEDO Safeline x-ray inspec-

tion systems can detect ferrous, non-ferrous,

stainless steel, glass and stone contaminants,

detect mass and check for missing or dam-

aged product inside closed packages.

Hi-Speed CheckweighingMETTLER TOLEDO Hi-Speed dynamic

checkweighing systems ensure 100% quality

control, minimize costly giveaway and give

you total peace of mind.

CI-Vision Machine VisionMETTLER TOLEDO CI-Vision inspection

systems ensure that products consistently

meet manufacturers’ quality standards and

specifications resulting in perfect product

presentation every time.

METTLER TOLEDO Connectivity Solutions inspection systems are offered with a variety of interfaces including

Ethernet TCP/IP, EtherNet/IP, Modbus TCP, USB, Serial, and our ProdX

software for a complete “off the shelf” solution. OMAC compliant PackML

is displayed locally and available over a variety of interfaces.

Learn All About Nercon’s Spirex™ ConveyorAt Pack Expo – Booth #C-4200

Neenah, WI – Nercon’s

Spirex™ Spiral Conveyor

provides a compact

solution to elevate

or lower a variety of

products in a production

line. The system gently

carries products

between floors or

machines or over aisles,

taking up minimal floor

space. Designed with a uniform slope and a continuously moving tabletop

chain, the Spirex Conveyor ensures smooth operation without disturbing the

product. This makes it ideal for fragile products like pies and other food items

that cannot handle impact or gripping. The Nercon Spirex is engineered to

convey trays, cartons, boxes, pouches, plastic containers, bottles and bundles

for the food & beverage packaging, household product packaging, and light

industrial packaging industries.

With attractive pricing, a robust design, and such versatility in packaging

applications, Nercon’s Spirex Conveyor is an ideal choice for new projects

or line modifications that require elevation changes. The bi-directional Spirex

can be configured in a variety of in-feed and discharge height combinations,

along with high and low speed applications. Operating speeds up to 150 feet

per minute are attainable depending upon the height change and product

size and weight. For wash-down environments requiring stainless steel

construction, the Spirex is the smart choice. It is also available in painted steel

construction. Adaptable to customer requirements, multiple lanes, slope and

chain widths are available ranging from 3 ¼” to 15”. The in-feed and discharge

location is also variable depending on the application. It even features the

flexibility for three different case sizes to be conveyed without any changeover.

Nercon is a leading manufacturer of standard and specially designed conveyor

systems. Their systems work with aluminum, tin, paperboard, cardboard,

paper, plastic or glass containers. All conveyors are designed to maximize line

efficiencies and reduce changeover times.

For more information on their Spirex Spiral Conveyor or any other systems, visit

them at Pack Expo – Booth #C-4200. (844)293-2814 www.nercon.com

Nercon Pentair Food & BeverageProcess Solutions from Südmo, Keystone Sanitary & HaffmansFor industries that demand uncompromising standards of safety, sanitation,

and performance, Pentair is at the forefront of innovation. Pentair’s process

valve, component, and quality control equipment meets stringent industry

requirements and successfully blends safety, quality and innovation.

Pentair’s Food & Beverage Process Solutions provide advanced technology

for today’s production plants. Südmo and Keystone Sanitary’s valve and

component range includes stainless steel mix proof, single seat, butterfly,

and specialty valves that meet the highest hygienic and aseptic standards.

Haffmans specializes in quality control equipment

for measuring carbon dioxide, oxygen, air,

alcohol/extract, and turbidity, as well as carbon

dioxide recovery.

Backed by serviceOperating a state-of-the-art production plant

requires a just-in-time manufacturing system,

minimized production losses and compliance

with tough quality regulations. This is why it is so

important to have scheduled service intervals,

trained service personnel and an adequate supply

of original spare parts. Pentair offers tailored

service plans to help you achieve maximum

plant efficiency.

Complete SolutionsPentair offers end-to-end solutions for the

food and beverage industries. For Pentair’s

customers, this means more time and resources

directed where they should be —making the

food and beverages to nourish a rapidly growing

planet.

Pentair’s proven products lead from a

technology point-of-view and include:

• Mix Proof / Aseptic / Butterfly Valves

• Valve Manifolds

• Product Recovery Systems

• CO2 / O

2 Quality Control Equipment

Contact:Pentair Food & Beverage North America

293 Wright Street

Delavan, WI 53115

Phone: 262.725.9026

Fax: 866.673.4621

[email protected]

www.sudmona.com

Keystone Butterfly Valve

Haffmans OGM In-line O2

Südmo Mix Proof Aseptic “Secure”




Precision PMD’s mission is to design

and manufacture reliable yet affordable

machines for the packaging industry. The

impact on your bottom line is not only

affected by the purchase price of the

machinery, but the up-time and life-span of

the machinery itself.

Designed to be versatile

and maintenance friendly,

Precision PMD machines are

manufactured for use in 24HR

operations in USDA and FDA

packaging facilities.

Precision PMD Complete Packaging Systems: We design and manufacture everything from

container D-Nesters, Conveyors, Piston Fillers,

Volumetric Pocket Fillers, Container Sealers and Lid

Applicators.

Our D-Nesters and Fillers can

be added to your existing

system or we can design and

manufacture a Complete

Packaging System tailored to

your specific needs.

Contact Precision PMD to discuss

how we can partner with your TEAM

to provide you with packaging

machinery that you can rely on today

and in the future.

Cup & Tray Application Expertise:• Cereal, Oatmeal, Nuts, Candy, Mac & Cheese

• Soup, Salsa, Humus, Pudding, Fruit Cocktail, Applesauce

• Fresh Salad including Spinach, Spring Mix (Complete Salad Tub

Packaging Systems)

• Macaroni Salad, Cole Slaw

• Family Meals, Frozen Entrees, IQF Vegetables and more

Precision PMD

Contact:Precision PMD, LLC.

9009 Freeway Drive, Unit 7

Macedonia, OH 44056

P: 330-908-0410

Toll free: 877-567-PPMD(7763)

[email protected]

www.precisionpmd.comSee us at PACK EXPO Las Vegas Booth # S-6125

A leading food industry machinery

supplier, Rovema North America

manufactures and supplies

equipment for dosing, vertical

form-fill-seal pouching, cartoning,

and final packaging operations,

primarily for the bakery, cereal,

confectionary, coffee, dry powder,

snack and frozen foods sectors.

At Pack Expo Las Vegas, Rovema

NA will showcase two advanced

BVC Series Vertical Form-Fill-

Seal (VFFS) Machines: The BVC 400 for the IQF/Frozen Food market, and

the BVC 260, which will be displayed running a Ropack standup bag. The

BVC 400 VFFS Bagging Machine is a continuous motion, dual axis servo,

vertical form-fill-seal machine offering broad flexibility in product sizes and

shapes demanded by the frozen food sector. The BVC 260 VFFS Bagging

Machine, also a continous motion, dual-axis servo packaging machine,

is capable of running up to 210 cycles per minute at a maximum forming

width of 260mm. Demonstrations of each machine will take place regularly

throughout the show.

The BVC Series incorporates

a patented “Sense and Seal”

quality control solution that

determines, for example, if

product is present in the cross

seal area and, if so, discharges

the bag without the application

of sealing pressure. The BVC

260 is equipped with Rovema’s

innovative “Premium-Seal”

system. Premium-Seal offers

the option to pre-heat and then

compress multilayered seal seam

packing material for optimum

tightness.

Rovema North America

Contact:Rovema North America

Pack Expo Booth C-4942

4366 Shackleford Road, Suite A

Norcross, GA 30093

Tel: (404) 640-5310


Website: www.rovema.com




Food and agricultural product producers need consistent high quality output

with minimal waste and downtime at an affordable price. Our sorters are

designed to meet this need.

The ASM VISION color sorter is

designed for reliability and performance

using the latest technologies. Distinctive

European engineering has attracted

hundreds of customers worldwide with

over 600 food sorting units installed.

The new software features a user-

friendly and intuitive touchscreen. The

LED lighting system increases the

contrast on the finest contaminants and provides a constant light quality. A

special chute design can process a higher throughput than conventional

sorting machines with the same operating width. The latest generation

of air-valves further reduce the loss of good material and offers a longer

service life.

The VISION INOX is full stainless steel for applications with this requirement,

such as salt.

The VISION sorter is available in 5 different sizes.

Our world-class lean manufacturing facility enables affordable pricing for

topnotch quality.

Our North American

headquarters and service center

is located outside Chicago to

provide local support.

____

The Labseed sorter helps

industry leaders in the seed

industry. It is designed for quick

batch changes in laboratories

and research institutes and

focuses on sorting accuracy and

smaller quantities.

Contact:Sesotec Inc

Eli Cannell

North American Sales Manager

224-279-5554

[email protected]


Sesotec Inc.

Revolutionary powder/liquid mixing

At PACK EXPO International in November, Silverson Machines will debut

its latest Flashmix powder/liquid mixer. The Silverson Flashmix is now two

times faster. Powder is incorporated into liquid at a rate of 500lbs/min. The

Flashmix incorporates breakthrough technology, allowing it to bring the

benefits of high shear mixing to new applications. It can be used with higher

viscosity mixes and at higher temperatures than was previously possible.

Unlike most powder/liquid mixers, which use vacuum to pull in powders, the

Flashmix literally forces powder into the liquid stream - there’s no venturi,

no vacuum. When the powder and liquid components are introduced

directly into the high shear zone of the mixer, they are subjected to intense

mechanical and hydraulic shear, which instantaneously combines them,

producing a homogeneous product without agglomerates. Stop by booth 7038 to learn more about the Flashmix and other Silverson high shear

mixers. Silverson High Shear mixers are available in laboratory to production

size models and are engineered precisely to enable seamless scale up.

If you can’t wait until November to see the new Flashmix, please watch one

in action at Silverson.com or contact a Silverson representative to arrange for

a free trial at (413) 525-4825 or [email protected]

Silverson Machines

Contact: Silverson Machines

East Longmeadow, Mass.

(413) 525-4825

www.silverson.com





SlipNOT® slip resistant stainless steel

products increase productivity for

food and beverage processing plants.

SlipNOT’s stainless steel products are

registered by NSF International, chemical

and corrosion resistant and provide

a hygienic solution for slippery areas.

Stainless steel products also withstand

the extreme heat of cookers or extreme

cold of cryogenics. In facilities where

chemicals, water and other vicious liquids are present, a slip resistant

surface is necessary to keep workers safe. SlipNOT manufactures a

variety of versatile products such as floor

plate, grating, ladder rungs and covers,

stair treads, nosings, drain covers and

many other products. SlipNOT products

are utilized for catwalks, crossovers,

walkways, platforms, trench covers, drain

covers and numerous other applications.

SlipNOT products are custom fabricated

to detailed specifications or can be

provided in stock lengths and widths.

SlipNOT recommends fabrication prior to SlipNOT coating, however,

SlipNOT products can be fabricated in the field. Customers can also

send in existing material to be coated methodically so there is no

downtime at the plant.

SlipNOT is a permanent solution; it will

not chip or wear quickly like traditional

methods of slip resistance. SlipNOT

products require little maintenance and are

cleaned by power washing or using a stiff

bristle brush. Stainless steel products will

not contaminate the end product and are

resilient to caustic cleaning agents.

Stainless Steel Flooring Products

Contact:Christina Molnar Metrose, Vice President

SlipNOT® Metal Safety Flooring

2545 Beaufait Street

Detroit, MI 48207

P: 313-923-0400

F: 313-923-4555

[email protected]

www.slipnot.com


Since 1976, T.D. Sawvel

has been providing creative

automated packaging

solutions for denesting, filling,

sealing and capping a wide

range of packaging shapes

and sizes from 1 ounce to 6

gallons.

T.D. Sawvel Company is

excited to announce the

continued expansion of our

“Triple-A” line of automated packaging equipment. Designed to meet or

exceed 3A, FSMA, and USDA standards, the following new models are

now available: Model 135PF-AAA Rotary Piston Filler for cups from 4 to 80

ounce, Model 119-AAA Lid Press for pails from 2 to 6 gallon sizes, Model

135TF-AAA Rotary Time Filler for cup sizes from 4 to 64 ounce, Model

1000-PLC-AAA Semi-Automatic Ice Cream Filler for pint to 3 gallon sizes.

We have many more “Triple-A” models in the pipe line so stay tuned.

If your equipment needs

do not require “-AAA” The

following New Models

may be of interest: Model

81-SRVO High Speed Dual

Lane Volumetric Filler for

cup sizes 6 to 64

ounce, Model 1000-6 Dual

Head Table Top Time Filler

designed for dosing cups from small continuous freezers.

Here at T.D. Sawvel we are continually improving and expanding our product

line. Whether it is more “-AAA” models or an “All New” high speed filling

line, there is always something on the drawing board. If you have not

checked out T.D. Sawvel Company lately, please do so. Thank you! Troy

Sawvel, President

Contact:Troy Sawvel

T.D. Sawvel Co., Inc.

5775 Hwy 12 W

Maple Plain, MN 55359

[email protected]

877-488-1816 toll free

763-479-5460

763-479-3517 fax

www.tdsawvel.com

TD Sawvel




The Austin Company Design-Build Leaders for Food & Beverage FacilitiesThe Austin Company is an international design-build firm offering a comprehensive portfolio of in-house architectural, engineering, construction management and consulting services. In addition, Austin offers value-added strategic planning services such as site location, transportation and distribution consulting, and facility and process audits.

Austin’s building solutions are more than just shade and shelter for your operations – they are facility solutions developed and implemented to make your operations better. We have been recognized as an innovative leader in the food and beverage industry since the early 1900’s. Our Food & Beverage Group is an experienced

and dedicated in-house team specializing in planning, designing and implementing safe, efficient and economical food and beverage facilities. From new construction to renovations and expansions, Austin offers advanced solutions for your facility needs.

Our services include:• Architecture/Engineering • Construction Management• Site Location• Design-Build• Process Engineering

Our global experience includes facilities for baking and snack foods, beverages, condiments, confectionery, diary, frozen foods, grains, fish, produce, and specialty items.

We have successfully implemented projects including:• Manufacturing and Production Facilities• Bottling Plants• Formulation and Packaging Plants• Research Laboratories• Bulk Storage Warehouses• Automated Distribution Centers

The Austin Company was founded in Cleveland, Ohio, in 1878. The firm became a wholly-owned subsidiary of Kajima USA in 2005 and is a proud member of the Kajima family of companies. Kajima Corporation is one of the leading engineering and construction contractors in the world.

Contact:Matt Eddleman

Sr. Vice President, Sales & Marketing

404.564.3962

[email protected]

www.theaustin.com


• Planning• Economic Analysis• Packaging Systems Services• Installation & Start-Up

With a diverse product line that includes vertical form fill seal (VFFS)

baggers, combination weighers / scales, depositors, and horizontal

cartoners, Triangle is your source for quality packaging machinery. As one

of the first companies in the world to manufacture VFFS bag machines,

Triangle helped set an unparalleled standard of excellence in the industry.

Family-owned and operated since 1923, today the family’s third generation

continues a tradition of superior engineering, world-class manufacturing,

and unparalleled customer support.

New for 2015: At Pack Expo 2015, Triangle is introducing an enhanced

version of Model XYT15 VFFS Bagger designed to run PrimaPak®

packages. PrimaPak® is an innovative stackable and reclosable package

style designed to replace rigid, pre-made containers or trays. In addition,

we are also introducing our Model XYT15-RJ VFFS Bagger, which can run

3-sided seal (Doy) bags, as well as pillow and gusseted bags, all on the

same machine!

VFFS Baggers: Available in intermittent or constant motion and 3 levels of

sanitation, including stainless steel, stainless steel washdown, and USDA/3A

models. Optional features include zipper applicators, ability to run quad-

seal stand-up bags, and Ultrasonic welding. Ultrasonic welding is a cold

sealing technology that provides multiple benefits to refrigerated and frozen

food packagers, including: material, energy, and labor savings; reduced or

eliminated leakers; and improved production and OEE.

Belt-Fed or In-Line Combination Weighers: Triangle Combination

Weighers provide expert product handling, superior sanitation, and non-

proprietary (AB) controls. Pair with a Triangle bagging machine for a

complete integrated system with a single HMI.

Tray Loading / Depositing Systems: Designed to deposit product into

a predetermined space in preformed bowls or in sectioned trays, Triangle’s

Tray Loading / Depositing System is ideal for small IQF products, fresh cut

produce, and more.

Triangle Package Machinery

Contact:Triangle Package Machinery Company

6655 W. Diversey Ave.

Chicago, IL 60707

Phone: (773) 889-0200

Fax: (773) 889-4221


Web: www.trianglepackage.com





Triple/S DynamicsTriple/S Dynamics introduced the Slipstick® Horizontal Motion Conveyor to the food processing industry in 1982. Today, with thousands of conveyors installed around the world, the Slipstick Conveyor and other accessory components set the standard of performance and sanitation in food processing.

Processors have many hot button issues including product breakage or degradation, sanitation and minimizing downtime. The Slipstick conveyor addresses all of these issues.

The Slipstick is an oscillating mechanical conveyor driven with a slow-speed, horizontal differential motion and requires no fiberglass springs or base frame. The motion is a slow-advance and quick-return cycle that glides product along the length of the conveyor. This motion does not impact the product so breakage is greatly reduced or eliminated. The product is conveyed gently, intact retaining any added seasonings or coatings.

This horizontal motion also provides sanitary conveying as the gliding of the product along the seamless one-piece formed conveyor pan discourages build-up of materials on the surface. The continuous sliding action on the

conveyor’s surface typically scours the pan clean so there’s less downtime.

In addition to the Slipstick, the Triple/S Dynamics Tex-Flex Vibratory Conveyor, equipped with a screening section, can remove overs and/or fines that enter the product stream before cartoning.

Food processors can rely on Triple/S Dynamics’ lineup of conveying equipment to solve their processing challenges.

Contact:Triple/S Dynamics, Inc.

P.O. Box 151027

Dallas, TX 75315-1027

214.828.8600

800.527.2116

Fax: 214.828.8688


www.sssdynamics.com

September 28-30, 2015 — Visit Urschel booth #S-7233 to view the latest in

food cutting technology including the newly-released Sprint 2™ Dicer. Other

machines featured include the Affinity® Dicer, E TranSlicer® Cutter, and the

M6 Dicer.

The latest addition to the Urschel line of dicers, the Sprint 2 builds on

the technology of the DiversaCut Sprint® Dicer and is inspired by the

longstanding Model G. Accepting an infeed product up to 6.5” (165.1

mm) in any dimension, the dicer offers a stainless steel sanitary design

throughout with the food zone completely isolated from the mechanical

zone. The new Sprint 2 offers an alternative to the Models G, G-A, GK-A, H,

or H-A Dicers with increased horsepower and benefits.

The Affinity® Dicer, the largest dicer Urschel manufactures, specializes in

the cutting of cheese and difficult-to-cut products such as meats with high

fat content. The U.S.D.A., Dairy Division accepted machine accepts a large

in-feed product size of up to 10”. Driven by a 25 HP gear motor with heavy-

duty gears and belts and equipped with a 5 HP VFD (variable frequency

drive) motor on the crosscut, the Affinity excels at delivering maximum

capacities.

Urschel has recently moved into a newly-constructed manufacturing/global

headquarters in Chesterton, Indiana, U.S.A. The 350,000+ square foot

state-of-the-art facility situated on 160-acres will allow for future growth of

the company. Founded in 1910, Urschel remains the global leader in food

cutting technology and continues to partner with food processors around

the world to develop and offer the latest in cutting machinery.

URSCHEL DISPLAYS THE LATEST IN FOOD CUTTING AT PACK EXPO IN LAS VEGAS

Contact:Urschel

1200 Cutting Edge Drive

Chesterton, Indiana 46304

Toll-free: 1-844-URSCHEL(877-2435)

[email protected]

www.urschel.com

See us at PACK EXPO Booth #S-7233




Pneumatic Conveying, Bulk Material Handling Solutions

Volkmann manufactures a range of high

quality, high performance vacuum-based

pneumatic conveying systems for the

transport of fine food powders, chemicals,

granules, pellets, tablets and other small

components. Volkmann conveyors are

driven by the patented Multijector®

multi-stage pump, which uses a series of

precision Venturi nozzles to increase both

the generated airflow from a given air supply

and to achieve a greater level of vacuum

thereby making it possible to convey in lean,

dense or plug flow conditions and do so

without segregation or damage. Conveying

distances can range up to 260 ft. as well as

heights of up to 115 ft., with custom systems

being built at times to accommodate higher

distances. In most applications; however,

the horizontal distances run to 150 ft. and

heights extend to 65 ft. Densities are most

frequently in a range between 6 to 150 lbs/

ft3. Volkmann vacuum conveyors have been

used for materials in such low ranges of

approx. 3 lbs/ft3 (e.g., fluidized pyrogenic

silica) to a high of 806 lbs/ft3 (e.g. uranium

compounds). It is even possible to have

custom conveying solutions for such

“critical materials” as wet, oily, adhesive,

bridging, hygroscopic, poor-flowing and

explosive materials. Even nanoparticles have been successfully transported

pneumatically by vacuum.

Suitable for the food, pharmaceutical, nutraceutical, and chemical industries,

Volkmann conveyors feature such standard features as “No-Tools”

disassembly and easy cleaning, all stainless steel contact parts, as well as

designs conforming to cGMP standards. The Volkmann series of vacuum

conveyors is industry leading with the additional benefit of ATEX certification

for explosion-proof applications.

In addition to their VS Series of vacuum conveyors, Volkmann will showcase

their new No-Tip Unloader, Post Hoist and High Containment Rip and Tip

Unloader at Pack Expo Las Vegas.

Contact:Volkmann, Inc.,

609-265-0101

www.VolkmannUSA.com;


Volkmann, Inc.,

Volkmann No-Tip Unloader

with Enhanced Features

WENGER EXTRUDERS AND DRYERS

Wenger Thermal Twin Screw

Extruders are unlike any

extruder on the market today,

with significant advantages

in design, capabilities and

efficiency. Higher levels of

thermal energy allow a more

gentle cooking process

than high-shear cook, and

therefore offer new opportunities in extruded foods. Products high in corn or

rice content can be processed without the stickiness typically encountered

in conventional extrusion systems. Ingredients may be fully cooked without

damage to the starch or protein matrix.

Wenger Dryers are

customized to exact needs,

including the optimum

dehydration of fruits and

vegetables. A dual plenum,

continuous conveyor

dehydrator provides high

volume, low-cost-per-ton

output, removing moisture

slowly, under controllable

conditions, to assure correct

final product moisture, color, taste and aroma. Humidity controls and variable

speed product conveyors regulate drying for proper product finishing. Multiple

pass conveyor configurations give great flexibility to process requirements as

well as plant design and layout. Heated airflow direction (up or down) may be

changed within each drying zone to meet varying product airflow demands.

Wenger’s experts will help you plan projects, develop product prototypes,

provide extrusion and drying demonstrations, perform laboratory analysis and

create processes for your new products.

See us at Booth #58447

Wenger

Contact:For more information:

Doug Baldwin, Director of Business Development

[email protected]

785-284-2133







SHOW PORTRAITS PRODUCTION AND PROCESSING EXPO SHOW PREVIEWS


153www.foodengineeringmag.com | Food Engineering | October 2014


Screw

any

today,

advantages

and

of

more

and

corn or

encountered

without

needs,

optimum

and

plenum,

high

low-cost-per-ton

moisture

controllable

correct

variable

Multiple

requirements as

may be

demands.

prototypes,

analysis and

Wire Belt, the leading developer of open

mesh stainless steel conveyor belts, has

been keeping your lines running for

over 85 years. Our conveyor belts are

extensively used for breading, battering,

frying, blanching, cooking, coating,

dusting, and cooling. Wire Belt is a

fourth-generation family owned company,

dedicated to serving our customer base

and remaining the industry leader in

stainless steel conveyor belt innovations

Wire Belt’s entire line of belting products are accepted by the USDA NSF/

ANSI/3-A hygiene standards. This is the only acceptance that can assure you

that you have the cleanest, safest conveyor belt available.

CONVEYOR BELTSWire Belt’s Versa-Link® conveyor

belt is perfect for poultry

processors. Versa-Link is one of

the most durable and open metal

belts available for light to medium-

duty applications. Versa-Link’s

unique spacing is designed to outperform competitive style belts especially in

bread crumb and flour applications, where typical belts are greatly stressed

and damaged during this process.

CONVEYORSWire Belt also offers CarrySmart® conveyors, its unique made to order line of

sanitary conveyors. The CarrySmart line includes Flex-Turn, Straight,

and Spreader or Converger conveyors. CarrySmart conveyors are custom

designed to accommodate your specific processing application. Other

advantages include open construction that is easy-to-clean, gentle product

handling, and one of the tightest transfer and smallest turning radius available.

To learn more about Wire Belt’s complete line of products, including our

CarrySmart conveyors, please visit us at www.wirebelt.com.

Wire Belt

Contact:Wire Belt Company of America

154 Harvey Road

Londonderry NH 03053

(603) 644-2500

[email protected]

www.wirebelt.com

See us at the IPPE Show Booth #7023


SHOW PORTRAITS PRODUCTION AND PROCESSING EXPO SHOW PREVIEWS


153www.foodengineeringmag.com | Food Engineering | October 2014


Screw

any

today,

advantages

and

of

more

and

corn or

encountered

without

needs,

optimum

and

plenum,

high

low-cost-per-ton

moisture

controllable

correct

variable

Multiple

requirements as

may be

demands.

prototypes,

analysis and

Wire Belt, the leading developer of open

mesh stainless steel conveyor belts, has

been keeping your lines running for

over 85 years. Our conveyor belts are

extensively used for breading, battering,

frying, blanching, cooking, coating,

dusting, and cooling. Wire Belt is a

fourth-generation family owned company,

dedicated to serving our customer base

and remaining the industry leader in

stainless steel conveyor belt innovations

Wire Belt’s entire line of belting products are accepted by the USDA NSF/

ANSI/3-A hygiene standards. This is the only acceptance that can assure you

that you have the cleanest, safest conveyor belt available.

CONVEYOR BELTSWire Belt’s Versa-Link® conveyor

belt is perfect for poultry

processors. Versa-Link is one of

the most durable and open metal

belts available for light to medium-

duty applications. Versa-Link’s

unique spacing is designed to outperform competitive style belts especially in

bread crumb and flour applications, where typical belts are greatly stressed

and damaged during this process.

CONVEYORSWire Belt also offers CarrySmart® conveyors, its unique made to order line of

sanitary conveyors. The CarrySmart line includes Flex-Turn, Straight,

and Spreader or Converger conveyors. CarrySmart conveyors are custom

designed to accommodate your specific processing application. Other

advantages include open construction that is easy-to-clean, gentle product

handling, and one of the tightest transfer and smallest turning radius available.

To learn more about Wire Belt’s complete line of products, including our

CarrySmart conveyors, please visit us at www.wirebelt.com.

Wire Belt

Contact:Wire Belt Company of America

154 Harvey Road

Londonderry NH 03053

(603) 644-2500

[email protected]

www.wirebelt.com

See us at the IPPE Show Booth #7023

Zeppelin Systems is a world leader in

the design, manufacture, and supply of

automated material handling systems

for powder and liquid ingredients. Our

systems are installed in world class

food and beverage companies around

the globe. Zeppelin Systems provides

engineered solutions customized to

the specific needs of our clients. We

emphasize the integration of dry and

liquid material systems into the rest of

the client’s manufacturing environment.

Competence and tradition are an

advantage for our customers. Zeppelin

Systems has been a source for complete solutions in process engineering and

material handling for more than 120 years.

Our areas of expertise include, but are not limited to, the following:

Bulk ingredients unloading (railcar, truck, containers, bags)

Bulk silos/tanks for dry and liquid ingredients

Pneumatic conveying (dilute and dense phase; vacuum and pressure)

Mechanical conveying (screws, trays, bucket elevators, belts)

Liquids unloading, storage, transfer and metering systems

Minor and micro ingredient systems

Pneumatic blending

Mechanical mixing

Continuous mixing system (CODOS®System)

Continuous and batch fermentation systems

Sugar handling and grinding systems

Process automation and controls

System software (PRISMA®, production resource information systems

management applications)

Rockwell Automation Solution Provider

Overall solutions from one source:

Equipment and components

Process technology

Automation and controls

Project management

Service and support

Contact:Stephen Marquardt - Sales Director – Food,

North & South America

E-mail: [email protected]

Zeppelin Systems USA

13330 Byrd Drive, Odessa Fl. 33556

Tel.: +1 813 920 7434

Fax: +1 813 920 3864

www.zeppelin-systems.com


Zeppelin

ZEPPELIN TECHNOLOGY FOR

LIQUID SPONGE AND SOURDOUGH

PRODUCTION – When using liquid sponge

a natural improver develops, ensuring

better tasting baked goods that stay fresh

longer. The process can be carried out in

batches or by using a CODOS® continuous

mixing system. Zeppelin’s systems deliver

consistently superior products.


C L A S S I F I E D M A R K E T P L A C E

EMPLOYMENT

www.CareersInFood.com

OVER 10,000 OPPORTUNITIES

The #1 Job Board for Food & Beverage Manufacturing Professionals

IN YOUR INDUSTRYwww.CareersInFood.com

AT YOUR FINGERTIPS

EQUIPMENT FOR SALE

Dave [email protected]

WWW.OSIJOBS.COM

OSIOptimum Search, Inc.

Excellence in Food Industry Executive Recruitment

Check our listings for plant/project engineers, plant operations, QA, R&D, sales, marketing and purchasing positions on our web-site.

Tim [email protected]

~ ~

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AnniversarySince 1970

Successfully assisting people in enhancing their careers in the Food Processing Industry since 1978. We specialize in the placement of Operations, Production, Engineering & Maintenance, Food Safety, Quality Assurance, and R&D Professionals.

Contact: Arnie Holder727- 461- 4868

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EQUIPMENT FOR SALE

DRUM UNLOADING EQUIPMENT

Knoll America, Inc.(248) 588-1500

www.KnollAmerica.com

➣ Up to 25 & 60 G.P.M

➣ Unloads 55-gallon drum in less than a minute

➣ Excellent for Viscous Material Material Material

Visit us online at foodengineeringmag.com


wabash POWER EQUIPMENT CO.

444 Carpenter Avenue, Wheeling, IL 60090

FOR SALE/RENT

BOILERS › 20,000-400,000 #/Hr.

GEARS & TURBINES › 25-4000 HP

WE STOCK LARGE INVENTORIES OF:

847-541-5600 FAX: 847-541-1279 WEBSITE: www.wabashpower.com

Air Pre-Heaters • Economizers • Deaerators • Pumps • Motors • Fuel Oil Heating & Pump Sets Valves • Tubes • Controls • Compressors • Pulverizers • Rental Boilers & Generators

DIESEL & TURBINE GENERATORS › 50-25,000 KW

24 / 7 EMERGENCY SERVICE

The ONLY Company Dedicated to REBUILT Scraped Surface Heat Exchangers

www.teammartinbrothers.com

Martin Brothers, Inc.1-800-652-2532 (318) 435-4581

•Trustonlytheoldest,mostexperiencedequipmentrebuilder•Relyonthelargestinventoryintheworld;dozensofmachinesinstock•Calloremailforfreeapplicationengineeringandquotes•Don’twaitonanymachineshoptotrytofixyourpart;getitNOWfromourhugeinventoryofusedand

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EQUIPMENT FOR SALE

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Recipe-controlled. IQ/OQ. CIP/SIP.Fast design/install. Reliable support.

Scan to learn more & get a free quote.

1-866-797-2660 www.RossSysCon.com

1-800-243-ROSS www.HighShearMixers.com

Scan to learn more & arrange a FREE trial.

HIGH SHEAR MIXERS

World’s Widest Selection,Single Stage to Ultra-High Shear!

1-800-243-ROSS www.StaticMixers.com

Scan to learn more & get a free quote.

STATIC MIXERS

For turbulent or laminar flow.LPD/LLPD/ISG for ultra-low ΔP & unlimited viscosity. Most in stock!


Further information on these companies can be found in the 2014-2015 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.

A D I N D E X

COMPANY PHONE NUMBER PAGE3-A Sanitary Standards, Inc. www.3-a.org 86A&B Process 888-258-2789 41ADI Systems, Inc. 800-561-2831 84Admix www.admix.com 37Alfa Laval www.alfalaval.com/gphe-us 39ALLPAX 888-893-9277 108A.M. King 704-365-3160 71Ampco Pumps Co. 800-737-8671 83Archon Industries Inc. 800-554-1394 90Atlas Copco 866-688-9611 69Austin Co., The www.theaustin.com 92APEC 616-374-1000 31Beckhoff www.beckhoffautomation.com 111Belt Technologies Inc. 413-786-9922 96BETE Fog Nozzle, Inc. www.bete.com 81Big D Construction www.-big-d.com BCBimba Manufacturing 708-534-8544 14Bradman Lake Group www.bradmanlake.com 50Breddo Likwifier 800-669-4092 IBCBühler Inc. 763-847-9900 116Bunting Magnetics 800-835-2526 28Caloris Engineering LLC 410-822-6900 89CDM Smith www.cdmsmith.com 88Clarion Lubricants www.clarionfoodsafety.com coverComplete Water Services, LLC 678-355-9270 90Cone Drive 888-994-2663 6Cubic Designs 800-826-7061 129Dorner Manufacturing 800-397-8664 18Douglas Machines 800-331-6870 52Dow Water & Process Solutions www.dowwaterandprocess.com 87Dur-A-Flex 860-528-9838 91Dynamic Conveyor 800-640-6850 53Eriez Magnetics 888-300-ERIEZ 34-35Festo Corp. 800-GO-FESTO 12Flexicon Coporation 888-353-9426 2, 19Flowtrend www.flowtrend.com 54FAM Conference www.foodautomationconference.com 99FE Webinars www.foodengineeringmag.com 79Fortress Technology www.fortresstechnology.com 22Fristam Pumps 800-841-5001 7Gamajet www.gamajet.com 82GE Software www.gesoftware.com 109GEA Group www.gea.com 97Goodway 888-364-3432 6GreCon 503-641-7731 130Hapman 800-427-6260 120Harpak Ulma 800-813-6644 125Haskell 904-791-4500 55Heat and Control 800-227-5980 67Heatec 423-821-5200 94Hinds-Bock 425-885-1183 38Hixson, Inc. 513-241-1230 1Hixson Webinar webinars.foodengineering.com 85Hoosier Energy 812-876-0294 76HR Green 800-728-7805 57IFS www.ifsworld.com 46IMA Dairy & Food 732-343-7600 20Industrial Magnetics 888-582-0821 36Ingersoll Rand www.ingersollrand.com/stresselsewhere 65

COMPANY PHONE NUMBER PAGEIntralox www.intralox.com 23JAX 800-782-8850 110JLS Automation 717-505-3800 70Kent Elastomer Products, Inc. 888-239-3940 58Key Technology 509-529-2161 115Kollmorgen 540-633-3545 113Leatherhead Food Research www.leatherhead.com 56Lubriplate Lubricants co. 800-733-4755 26Marchant Schmidt Inc. 920-921-4760 16, 17Marion Process Solutions 800-397-6371 57Masosine Pumps 800-282-8823 100Master Bond 201-343-8983 49Material Transfer & Storage 800-836-7068 112McCloud Services 800-332-7805 59Mettler Toledo www.mt.com/pi 42Meyer Industries, Inc. 210-736-1811 43Mitsubishi Electric www.mitsubishirobotics.com 107Multi-Fill 801-280-1570 127Nelson Jameson 800-826-8302 59Nercon 844-293-2814 60Pack Expo Las Vegas www.packexpolasvegas.com 119Paxton Proudcts 800-441-7475 47Peco-InspX 877-722-6875 25Pentair www.sudmona.com 117Polyguard 214-515-5000 53Polytron 855-754-7659 30Precision PMD 877-567-PPMD 24Pure Bioscience www.purebio.com 95Rovema 404-640-5310 73Ross, Charles & Son Co. 800-243-ROSS 13, 131Schenck Accurate 800-558-0184 4Sesotec 224-208-1900 72Sigma 800-578-5060 48Silverson 413-525-4825 29SlipNOT 800-754-7668 98Specialty Equipment 713-467-1818 105Spiroflow Systems, Inc. 888-909-7674 5Spraying Systems Co. 800-95-SPRAY 11SPX 800-252-5200 IFCSTOCK America 262-375-4100 114Sudmo Pentair www.sudmona.com 117Summit Industrial Products 800-749-5823 40T.D. Sawvel Co. Inc. 877-488-1816 32 Tekleen Automatic Filters Inc. 800-336-1942 33Terlet USA 800-965-6065 10Tetra Pak Webinar www.webinars.foodengineeringmag.com 93Therm Omega Tech 877-379-8258 74Tomra Sorting Solutions www.tomra.com/food 33Triangle Package Machinery Co. 800-621-4170 44Triple S Dynamics, Inc. 877-542-8010 9True Clean www.trueclean.us 51Unifiller 888-733-8444 123Urschel Laboratories 219-464-4811 103Volkmann, Inc. 609-265-0101 118Weitz www.weitz.com 45Wenger www.wenger.com 128Wire Belt Company of America 603-644-2500 75York Saw & Knife 800-233-1969 61Zeppelin Systems 813-920-7434 49


E N G I N E E R I N G R & DWayne Labs, Senior Technical Editor

Lubrication keeps wheels turning in flash freezing applications

FE: The patent attributes Terry L. McAninch of Birko as the inventor. Can you tell us a little about his background?Dr. Jeremy Adler: Terry is the current vice presi-dent of research and development at Birko. He has worked for Birko for 41 years, during which he has authored or co-authored 11 issued patents. He is truly the foundation of Birko’s R&D efforts and an industry expert in cleaning, sanitation and lubrication.

FE: How did you come to develop this lubrication?Adler: A majority of our R&D projects come direct-ly from identifying customer problems and trying to solve them. In this instance, we had a customer that was losing significant trim yield on hog carcasses because black specs had to be trimmed from the carcasses. Upon investigation, we realized the black specs were iron particles from the gambrels that spalled [chipped or flaked] onto carcasses after pass-ing through the blast freezer. This spalling is caused when water adheres to a gambrel and freezes solid during blast freezing. The freezing of the water spalls iron flakes off the gambrel and onto the carcasses.

FE: What special lubrication problems needed to be solved?Adler: Gambrels in a hog plant are cleaned and lubricated between uses. For the lubrication step, oil is floated on top of a water bath. Floating the oil on the water bath decreases the amount of oil needed for lubrication, saving the plant money. During the lubrication process, the gambrel is dipped into the tank passing through the oil layer and into the water. The gambrel is then passed through the oil layer again as it is raised out of the tank. It is then blow-dried to remove excess oil. Any water from the lower layer of the lubricating bath that is not displaced by the oil remains on the gambrel. This residual, or undisplaced water, can lead to gambrel spalling. Our goal was to find an oil mixture that would displace the water on the gambrel to minimize the amount of spalling. After several trials in the lab, we formulated Frostlube, which contains the precise amount of silicon oil to preferentially adhere to metal to displace water.

FE: How do you balance real-world lubrication needs with food safety requirements?Adler: When formulating oils for lubrication, we use only products approved for incidental food

For the meat packing industry, lubrication for conveyors must maintain adequate lubricity in freezing cold areas, provide corrosion resistance and be safe to use.

Dr. Jeremy Adler, Birko director of technology and innovation

Pork processing, like any live protein processing, is not a nice environment for humans or

machines. Humans, however, can dress properly or take breaks, but that isn’t the case for

machinery, especially gambrels and rail surfaces on overhead conveyor systems. This machinery

must run in hostile, cold environments—and keep on running.

Unfortunately, finding lubrication that survives a pork processing environment, especially blast

freezers, hasn’t been easy. But now, Birko Corporation is offering a product line for pork process-

ing applications including hog scalding, defoamer agents, pathogen reduction treatments and

chemistries for gambrel cleaning and oiling.

The lubrication solution, known as Frostlube, is designed for the gambrels and rails in

blast freezing applications. It received a US patent (8716205) last year. We caught up with

Dr. Jeremy Adler, Birko’s director of technology and innovation, and asked him for some specifics

about the product.


E N G I N E E R I N G R & D

contact. Given this, from a chemistry standpoint, there are really no food safety issues, as long at the product is applied as directed. Ultimately, Frostlube decreases the amount of trimming during the visual inspection of a carcass, increasing carcass yields.

FE: What level of viscosity should a lubrication treatment have for gambrel/rail applications? Adler: We tend to define our gambrel and trolley lubricants by their lubricity and load-bearing properties. Lubricity is the lubricant’s ability to reduce friction, thus making it easier to move the loaded gambrel along the rail. The friction can be between the rail and the gambrel wheel or the gambrel wheel and central axis pin as the gambrel travels along the rail. The load-bearing capacity is the lubricant’s ability to adhere and remain on the surface to hold, or separate, the gambrel weight from the rail. Therefore, a lubricant’s load-bearing capacity is directly proportional to the viscosity. We design our lubricants to have the necessary load-bearing capacity and lubricity for the carcass weights and range of temperatures found in the processing environment.

FE: How does a lubricant’s viscosity change depending on environmental temperatures?Adler: In general, the viscosity of fatty acid and mineral oils, which are [used in] the most common type of food industry lubricants, increases as the temperature is lowered. How-

ever, silicon oils tend to have a viscosity that is less affected by temperature to the point where they are almost temperature independent in the range of temperatures found in processing environments. Simply put, silicon oils stay fluid during pork processing at 180°F and even during blast freezing at -28°F.

FE: How do you keep the lubrication from dripping onto the carcass immediately below it? Adler: The key is to develop a lubricant that does not thin out and drip. To inhibit dripping, we have incorporated an oil thickener into the formula of Frostlube. Additionally, we for-mulated the lubricant so it is thick and unlikely to drip at pork processing temperatures. For the oil to be applied quickly and uniformly, it must be applied hot. The lubricant application tank I previously described is around 180°F. After application, the oil’s temperature drops, and it forms a gel on the gambrel.

FE: How do you create a formula safe for incidental contact with meat?Adler: We use only products approved by FDA and USDA for incidental contact with food, specifically, in this case, pork. If our lubricants come in contact with an edible product, that product is still safe to consume. Nonetheless, when a lubricant does come into contact with an edible product, USDA inspec-tion procedures dictate that the product must be trimmed to remove the lubricant. FDA and USDA approval makes choos-ing the lubricant components easy: Either they are OK or not OK to use. However, it also limits the choice and possible func-tionality of the lubricant.

FE: When it’s time for washdown, does the lubricant stay put, or does it need to be reapplied?Adler: Gambrels are cleaned and oiled between uses. The cleaning process is dependent on the gambrel metal composi-tion and usually includes a cleaning agent applied at a high temperature. These cleaning processes, whether the plant is using steel or aluminum gambrels, clean the gambrels includ-ing the lubrication. Then, the gambrels are oiled before they are used again.

FE: Would this lubrication technology be suitable for gambrel/rail conveyor systems in other food applications?Adler: Yes, Frostlube can be used in poultry and beef process-ing plants. But, since these plants do not use blast freezers and, for the most part, don’t have spalling issues, they would not experience the technical benefit of the lubrication.

FE: Are there any similar products on the market?Adler: Frostlube was designed specifically for a pork proces-sor that uses a blast freezer before cooling carcasses. We are unaware of any similar products in the poultry, beef and pork markets. It is patented technology, so we can protect this prod-uct for several years. ❖

The patent for Birko Frostlube describes an improved lubricant for use with a conveyor in a meat packing plant meeting the requirements of adequate lubricity, drip resistance, safety, rust resistance, economy of manufacture and use, and the ability to be removed by cleaning methods. Source: US PTO.

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Documents

Food Engineering 2015 09