Food Engineering March 2011

EXCLUSIVE REPORT: MAKING THE RIGHT CHOICE WITH WIRELESS SMART SENSORS March 2011 | www.foodengineeringmag.com THE MAG...

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EXCLUSIVE REPORT: MAKING THE RIGHT CHOICE WITH WIRELESS SMART SENSORS March 2011

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www.foodengineeringmag.com

THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT

Food Safety Audits

Meeting the CertiÀcation Challenge Head On

ALSO THIS MONTH ` TEAM APPROACH NEEDED FOR COMPLEX AUDITS ` 3D PRINTING WITH SERENDIPITOUS FOOD APPLICATIONS ` TECH UPDATE: COOKING & FRYING

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MARCH 2011

www.foodengineeringmag.com

FEATURES COVER STORY

44

Food Safety Audits: Meeting the Certification Challenge Head On Certification programs under the GFSI umbrella are taking root in North America, though not without some growing pains and process changes for food manufacturers.

59

Making the Right Choice With Smart Wireless Sensors Smart sensors have been around for a long time, but when combined with wireless capabilities, the sky’s the limit.

69

Tech Update: Cooking & Frying Improved energy efficiency, fun shapes, healthier eating: myriad market demands are driving changes in commercial cooking and frying systems.

50 DEPARTMENTS 8

Editor’s Note

10

Calendar of Events

13

Manufacturing News Walmart leads market drive to healthier food.

17

Food Packaging China’s hybrid approaches to packaging and production

23

84

Food Safety A team approach is needed for complex audits.

29

Technology Sourcebook Focus on Extrusion and Pest Control

Connect with FE on Facebook

76

www.facebook.com/FoodEngineering

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

Join FE’s Group on LinkedIn

Field Reports ASRS minimizes energy usage, improves efficiency.

77

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Engineering R&D 3D printing with serendipitous food applications

Food Engineering Magazine

www.foodengineeringmag.com | Food Engineering | March 2011

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You g n i v i sG t n e i d Ingre

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? S E R TMA

www.foodengineeringmag.com EDITORIAL Joyce Fassl Editor in Chief [email protected], 610-436-4220 ext. 8519 Kevin T. Higgins Senior Editor [email protected], 847-405-4045 Wayne Labs Senior Technical Editor [email protected], 215-345-4548 Richard Stier, Morgan Smith, Jaan Koel, Allen Merritt, Mark Huffman, Olin Thompson Contributing Editors ART & PRODUCTION Karla Fierimonte Art Director [email protected] Suzanne Fairman Advertising Production Manager [email protected], 253-946-6854 MARKETING Marge Whalen Food Automation & Manufacturing Conference Manager [email protected], 847-405-4071 Amy Kozyra Marketing and Event Coordinator [email protected], 847-405-4022 Chris Frost ProcessTechnologyXchange [email protected], 952-224-4390 Jill L. DeVries Corporate Reprint Manager [email protected], 248-244-1726

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LIST RENTAL Rob Liska List Manager (postal) 800-223-2194 x726, [email protected] Shawn Kingston Account Manager (email) 800-409-4443 x828, [email protected] AUDIENCE DEVELOPMENT Amy Schuler Group Audience Development Manager Megan Neel Corporate Fulfillment Manager Carolyn M. Alexander Audience Audit Coordinator FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT: Tel. 847-763-9534 or Fax 847-763-9538 or e-mail [email protected]

FOOD ENGINEERING Volume 83, Issue 3 (ISSN 0193-323X) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

BNP Media See Food Master, p. 5-7

Helps People Succeed in Business with Superior Information

Imprecise water application on bread dough caused a significant QC problem for a leading bakery. Application of too much water caused the dough to rise unevenly while too little water resulted in the sesame seeds not sticking properly. In both cases, the baked bread had to be scrapped. PulsaJet® spray nozzles controlled by an AutoJet® Model 1550 Modular Spray System provided the precision required to ensure bread quality. The spray controller adjusts the flow rate of the nozzles based on line speed. The proper volume of water is applied uniformly even when conditions change. The hydraulic PulsaJet nozzles with positive shut-off prevent dripping, misting and overspray.

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www.foodengineeringmag.com NORTH AMERICA SALES Patrick Young Publisher & District Sales Manager 600 Willowbrook Lane, Suite 610 West Chester, PA 19382 [email protected] Tel: 610-436-4220, ext. 8520; Fax: 610-436-6277 Mid-Atlantic Territory: CT, Eastern PA, NJ, NYC and LI, VA, MD, DE, Washington DC Paul Kelly District Sales Manager 155 N. Pfingsten Rd., Suite 205 Deerfield, IL 60015 [email protected] Tel: 847-405-4048; Fax: 248-502-1017 Midwest and Northeast Territory: Northern IL, WI, MN, IA, KS, MO, SD, ND, CO, WY, NE, TX, OK, NM, AR, NH, VT, MA, RI, ME, Saskatchewan Brian Gronowski District Sales Manager 13973 Meadowlark Ln. Newbury, OH 44065 [email protected] Tel: 440-564-5732; Fax: 440-564-5734 Midwest and Southeast Territory: OH, IN, WV, KY, TN, MI, NY, Western PA, FL, GA, NC, SC, AL, Southern IL, MS, LA, Ontario, Quebec Wayne Wiggins Jr. District Sales Manager 454 Funston Avenue San Francisco, CA 94118 [email protected] Tel: 415-387-7784; Fax: 415-387-7855 West Coast Territory: AZ, CA, OR, WA, AK, UT, ID, HI, British Columbia

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Directories Nikki Smith Human Resources Marlene J. Witthoft Conferences & Events Emily Patten Clear Seas Research Beth A. Surowiec

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March 2011 | Food Engineering | www.foodengineeringmag.com

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EDITOR’S NOTE

Pass the meatballs, but hold the bugs

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

ven though most sectors of the food and beverage manufacturing industry fared well during the recent economic meltdown, food makers continue to be challenged by an evolving, complex and sometimes strange marketplace. According to the United Nations Food and Agriculture Organization (FAO), world food prices surged to an historic peak in January 2011. Higher food process can affect a variety of concerns, from world hunger and political uprisings to job market stability for all Food Engineering readers. The food industry experienced even more bad news this month with the announcement that global warming will continue to wreak havoc on food safety. During this year’s meeting of the American Association for the Advancement of Science, a Michigan State University (MSU) professor said climate change is already affecting the safety of the world’s food supply, and unless action is taken, it’s only going to get worse. MSU Professor Ewen Todd said there are already a number of examples. One is Vibrio, a pathogen typically found in warm ocean water that is now becoming more common in the north as water temperatures rise.

According to a Wall Street Journal report, insects may become our future meal of choice as food prices rise. Insects require less water during processing, need less feed and produce less greenhouse gases than our current popular protein food choices such as meat and poultry. The WSJ article says insects may be used as a replacement for meat in meatballs and sauces or mixed into prepared foods to boost nutritional value. The article goes on to say dry-roasted insects could also be used as a replacement for nuts in baked goods. Maybe there’s hope for the childhood obesity battle after all. Chicago students are not eating the healthy meals now sold at their schools, and sales are plummeting. Perhaps these kids would love to take a bite out of actual mealworms, not the gummy candy variety. Millions of people in developing countries already eat insects. In fact, some governments are spending millions of dollars researching insects as a food source. Check back in 2021. We may well have a new special section in Food Engineering devoted to insect processing right next to the article on pest control. In a truly sustainable environment, anything is possible. Bon appétit. ❖

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

8

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


Alex Peele Director of Project Engineering Interstate Brands Corp.

Dan Sileo Vice President, Manufacturing Sunny Delight Beverages

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

David Haase Vice President of Operations WILD Flavors

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CALEN DAR APRIL 2011 3-6: Food Automation & Manufacturing Conference and Expo; Ritz-Carlton, Palm Beach, Palm Beach, FL; Food Engineering, www.foodautomationconference.com 13-16: AMI International Meat, Poultry and Seafood Industry Convention and Exposition; McCormick Place, Chicago, IL; American Meat Institute; 703-259-6118; www.amiexpo.com 19-21: Food Safety Summit; Washington DC Convention Center, Washington, DC; BNP Media; 847-405-4063; www.foodsafetysummit.com

MAY 2011 3-6: Fundamentals of Food Science; Penn State University, University Park, PA; Office of Conferences and Short Courses, Penn State University; agsci.psu.edu/fundamentals 10-11: TD-NMR Applications in the Food Industry: Compositional Analysis, QC, R&D and Safety; NC State University, Raleigh, NC; Dept. of Food, Bioprocessing and Nutrition Sciences, NC State University; 919-515-2957; www.ncsu.edu/project/foodengineer/ short-course 12-18: Interpack 2011; Düsseldorf, Germany; Interpack Processes and Packaging; www.interpack.com 17: Continuous Flow Thermal Processing of Multiphase/Particulate Foods; NC State University, Raleigh, NC; 919-515-2957; www.ncsu.edu/project/foodengineer/short-course

• Vertical Unit = Small Foot Print

22-26: 11th International Congress on Engineering and Food; Athens, Greece; ICEF; www.icef11.org/main.php?general

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JUNE 2011

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11-15: IFT11 Annual Meeting & Food Expo; New Orleans, LA; Institute of Food Technologists; 312-604-0238; www.ift.org 16-17: Workshop on Novel Sampling and Sensing for Improving Food Safety; GTRI Conference Center, Atlanta, GA; Food Processing Technology Division, Georgia Tech Research Institute; www.foodsensing.gatech.edu 21-23: PACKEX 2011; Toronto Congress Centre, Toronto, ON; Canon Communications; 289-971-0534; www.canontradeshows.com

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SEPTEMBER 2011 11-14: ProcessTechnologyXchange; The Lodges at Deer Valley, Park City, UT; VerticalXchange; 952-736-9370; www.pt-xchange.com 19-21: International Dairy Show; Georgia World Congress Center, Atlanta, GA; International Dairy Foods Association; www.dairyshow.com

April 3-6, 2011 The Ritz-Carlton Palm Beach, Florida For more information, see pages 42-43.

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MANUFACTURING

`NEWS PLANT OPENINGS & EXPANSIONS

Market drives healthier food

Schar, Italian manufacturer of gluten-free foods, will build its US headquarters and a processing plant in Logan, NJ. Construction on the new 60,000-sq.-ft. structure is expected to begin in early spring. The $15 million facility will open in 2012.

Atkinson Candy Company has begun construction on a new 1800-sq.-ft. sugar liquefaction plant in Lufkin, TX. Rather than importing liquefied sugar from Louisiana, the company will use granular sugar and liquefy it.

The Nashville Bun Company, which produces rolls and buns for companies such as KFC and McDonald’s, has begun construction of a 25,000-sq.-ft., $7 million expansion, with production on the new line slated to begin in June 2011.

Bindi USA, Italian desserts producer in Totowa, NJ, broke ground on a new cold-storage facility in Kearny, NJ. The first phase of the 64,000-sq.-ft. structural steel facility is expected to be finished in late spring or early summer and includes a warehouse, office space and an interior loading dock. The second phase will include production and additional warehouse space.

Merchants Foodservice will add 32,000 sq. ft. of cooler and freezer space to its Jackson, MS distribution center. The expansion consists of one-million cu. ft. of freezer space and 240,000 cu. ft. of cooler space.

W

almart recently launched a comprehensive program to provide its customers with healthier and more affordable food choices. The program builds on the success of First Lady Michelle Obama’s Let’s Move campaign to make healthy choices more convenient and affordable for families. In working with its suppliers, Walmart outlined five key elements of the plan. 1. Reformulating thousands of everyday packaged food items by 2015 by reducing sodium 25 percent and added sugars ten percent, and by removing all remaining industrially produced trans fats. 2. Making healthier choices more affordable, saving customers approximately $1 billion per year on fresh fruits and vegetables through a variety of sourcing, pricing and transportation/logistics initiatives that will drive unnecessary costs out of the supply chain. The retailer intends to reduce or eliminate the price premium on key “better-for-you” items (such as reduced sodium, sugar or fat products). 3. Developing a strong criterion for a simple front-of-package seal that will help consumers quickly identify healthier food options. 4. Providing solutions to address food deserts by building stores in under-

` First Lady Michelle Obama joins students for a “Let’s Move!” Salad Bars to Schools launch event at Riverside Elementary School in Miami, FL. Source: Official White House Photo by Chuck Kennedy.

served communities that are in need of fresh, affordable groceries. 5. Increasing charitable support for nutrition programs that will help educate consumers about healthier food solutions and choices. “No family should have to choose between food that is healthier for them and food they can afford,” says Bill Simon, Walmart US president and CEO. Simon says the retailer is committed to working with processors, government and non-governmental organizations to provide both nutritional and cost-effective solutions for its customers. Reformulating products will be a key effort for processors. Walmart expects to reduce sodium by 25 percent in a broad category of grocery items including grain products, luncheon meats, salad dressings and frozen entrées; reduce added sugars by 10 percent in dairy items, sauces and fruit drinks; and remove all remaining industrially produced trans fats in all packaged food products.


13

MANUFACTURING

`NEWS INDUSTRY & PEOPLE Campbell

Soup

Company

announced a new North American management team for its healthy beverages, soup and simple meals businesses. The team reports to Sean Connolly, president Campbell North America. The

new members include Ed Carolan, vice president and general manager, soup and simple meals; Tim Hassett, senior vice president, sales, Campbell North America; Darren Serrao, vice president and general manager, beverages and break-

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tors agreed to divide the company into two separate, publicly traded companies. The separation is expected to be completed in early 2012. Sara Lee’s North American retail and North American foodservice businesses (excluding the North American beverage business) will be spun off into a new public company that will retain the Sara Lee name. Its brands will include Sara Lee, Jimmy Dean, BallPark, Hillshire Farm, Chef Pierre and State Fair. The other yet-to-be-named company will consist of Sara Lee’s current international beverage and bakery businesses, as well as the North American beverage business. Its leading brands will include Douwe Egberts, Senseo, Pickwick, Maison du Café, L’OR, Café Pilão, Marcilla and Bimbo.

utive vice president, strategy.

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14

Sara Lee Corporation’s board of direc-

Sam Rovit joined Kraft Foods as exec-

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through innovation; and Chris Slager, vice president and general manager, North America foodservice.


Frozen food maker Rich Products has acquired frozen dessert and ice cream cake maker Celebration Foods.

POWER Engineers, Inc. announced the addition of Darryl Wernimont to the company’s food, beverage and consumer products facilities team. Wernimont has more than 30 years of experience in conventional, extended-life and aseptic processing and packaging projects. Sandridge Food Corporation was named the 2010 Refrigerated Foods Processor of the Year by Refrigerated & Frozen Foods (RFF) magazine. PepsiCo, Inc. completed the acquisition of approximately 66 percent of the outstanding shares of Wimm-BillDann Foods, a Russian branded food and beverage company for approximately $3.8 billion, increasing PepsiCo’s total ownership of Wimm-Bill-Dann’s to approximately 77 percent.

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

One world, one image

`

China has a hybrid economy, and its food sector also borrows the best approaches to both packaging and production.

T

he global village usually refers to commercial trade, but it also is an apt description of the motivations and responses people exhibit to processed foods. To illustrate, consider Hedetang fruit juices, a retail line sold primarily through Walmart stores in China and geared toward quality-conscious people. Per capita consumption of fruit juice is a fraction of the world average, but “with the expansion of the middle class in China, combined with already health-consciousness of Chinese consumers, the demand for fruit juice will continue to increase,” according to Spring Liu, CFO of Skypeople Fruit Juice Inc., a Florida indirectholding company for the Hedetang brand and the production facilities that make it. While those facilities have PET bottling capabilities, the line of premium juices are filled in 280mm and 500mm

` With health-consciousness and incomes rising in China, Skypeople Fruit Juice is betting its Hedetang kiwi and other high-end juices will appeal to Walmart shoppers in Beijing and other cities. Source: Skypeople Fruit Juice Inc.

glass. “Glass bottles are usually for higher-quality juices in China,” Liu explains. Popular flavors such as apple and pear are included, but Skypeople is distinguishing itself with exotic combinations of kiwi and mulberry. “Kiwi is called king of vitamin C in China, and mulberry is famous for its antioxidant,” says Liu. “There is a market potential for our beverages in foreign countries, especially our kiwi and mulberry juice,” though meeting domestic demand for the premium-priced juices ($1.79 for the half-liter) is the current focus. The kiwi is produced in Shaanxi Province at a state-of-the-art facility previously spotlighted in Food Engineering (“Not [just] about size,” June 2005). The plant, acquired by Skypeople in 2006, was built in the middle of a 1,647 acre kiwi plantation, cultivated specifically to supply the facility. Advanced technologies include an open-channel, tubular membrane R/O system to concentrate kiwi juice for export to industrial customers in the US and other markets. Skypeople regards the system as one of its six key technologies. Skypeople’s path to retail branding provides a glimpse into the evolution of the Chinese food sector’s incorporation with the global market. US operations began in 1998 as an Internet consulting service, with food acquisitions commencing later. Marketing is driving the Hedetang brand’s growth, but “modern equipment and technology employed at our production factories,” along with “the strategic locations of our manufacturing facilities,” are the key to commercial success, the company states in its 10-K filing with the SEC. “Equipment and technology help us ensure product quality, control costs and allow us to meet international juice standards such as ISO 9001, HACCP and Kosher.” ❖ For more information: Spring Liu, Skypeople Fruit Juice Inc., 818-390-1272, [email protected]


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

Drop the knife

S

ealed Air’s Cryovac division began introducing Grip & Tear bags for different food applications in 2007, with varying degrees of acceptance. Leak-resistant bags for whole fresh poultry may be the first bona fide home run. Focus group research confirms the bags have particular appeal when people have to handle raw poultry, according to Don Smith, marketing manager at Duncan, SC-based Cryovac. Processors are sitting up and taking notice, with Perdue and Butterball expanding to both consumer and deli case applications. Using a knife to open a bag is as much a hazard in the workplace as it is in the home, after all, and knifeless opening of skin-tight bags is the primary benefit of the bags. Tabs at the top of the bag initiate package removal, but the “straight-line tear propagation” that results in a clean vertical tear line is a function of the bag’s polymer matrix, Smith explains. “Getting the market educated is the biggest challenge” to expanded use, he adds. Gaining acceptance for innovation from food packagers can be a drawn-out process, making the fresh poultry bag’s early success gratifying.

` Butterball and Perdue are early adopters of Cryovac’s grip & tear poultry bags.

Oven-Ease is a cook-in bag that can be used in either a microwave or convection oven. Retention of juices and ease of preparation are the bag’s appeal, but applications remain limited. One issue is retail placement: Because there are no comparable cookin bags, retailers are uncertain where to stock those products, and shoppers don’t readily understand the value-added proposition and don’t have time to orientate themselves on the run. ❖ For more information: Don Smith, Cryovac, 800-391-5645

Solutions for you and you alone. No

ceptions.

IIf there h iis one thing hi 0 years off iindustry d i h h us, iit’s ’ that h products d hi h over 50 experience have taught which may have worked in the past may not be sufficient to provide adequate lubrication in the h ffuture. At JAX lentless in our quest st to provide vid you with i h the he mostt inno ive and indi id li d JAX, we are relentless innovative individualized llubricant lub i l i d the h lif hi d d i d iincrease production. d i solutions to extend life off your machinery, reduce downtime and Just a our needs are ever-ch i , so is our line of iindustrial d strial llubricants b icants – because af ll as your ever-changing, after all, the th h thing hi ki l i there iis no such as a cookie-cutter solution.

800.782.8850 www.jax.com

See Food Master, p. 76-77 FEX09074JAX.indd 1

18


8/8/07 10:46:17 AM

S U C C E S S

S T O R I E S

HOW A VE MAG SALAD DE P OSITOR

eliminated HAND-LABOR a n d i n c r ea sed P R O F I TA B I L I T Y A TRUE STORY: A local customer visited Reiser to test our AMFEC equipment to mix his gourmet seafood salad. The test ran quite successfully. The customer then explained how his delicate mixture would be hand-scooped into plastic containers and he challenged us to develop a more cost-efficient solution. We suggested a Vemag Depositor with a dripless valve attachment. At first, the customer was skeptical – he thought the machine would damage the large chunks of seafood that his customers loved. However, the labor costs to hand-scoop were eating away at this product’s profitability, so he decided to give the Vemag a shot. We explained that the Vemag’s positive displacement double-screw pump would portion his product extremely gently without damage. He was pleasantly surprised to see that the portioned product from the Vemag Depositor was indistinguishable from the hand-scooped product. Plus, the Vemag delivered exact-weight portions with no giveaway. The customer was thrilled to leave Reiser with a solution to his mixing problem and his labor and giveaway issues.

A VEMAG DEPOSITOR CAN GREATLY REDUCE YOUR LABOR COSTS Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 www.reiser.com

Leading the food industry in processing and packaging solutions.

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

Surf’s down for bottles

S

lip sliding away applies to both glass bottles and workers in many bottling departments because of the need to keep conveyor belts lubricated and containers upright while they twist, turn and accumulate. As line speeds ramp up, so do the breakage rate and the volume of liquid run-off on the floor. Engineers at St. Paul, MN-based Ecolab Inc. have been chipping away at the problem for four years, gradually adding new controls and lubrication options that are bundled under the DryExx conveyor management umbrella. The newest element of the program is DryExx GS, a lubricant designed specifically for glass containers on stainless steel conveyors. It complements a lubricant of phosphate ester, amine salt and a nonionic surfactant that is touted as appropriate for multiple conveyor surfaces and container materials, including PET. Ecolab’s lubrication program grew out of manufacturer requests “to take water out of non-value added applications,” according to Nels Anderson, senior marketing manager, beverage, brewery & aseptic. “We identified [bottle conveying] as one of the water hogs.” Greater precision is required when metering out the

` Specialty lubricants, coupled with an innovative control system, minimize liquid waste and broken bottles. Source: Ecolab Inc.

lubricants, making the control system a critical component when switching from conventional lubrication systems. About 1,200 bottling lines around the world have converted to Ecolab’s dry lubricants, with typical savings of 600,000 to 1 million gallons of water per line per year. Those numbers look good in a corporate social responsibility report, but the workplace benefits of fewer slips and falls and less clean-up may be the bigger payoff. “Many customers say they did it for water savings and operational efficiency, but at the end of the day, those are the greatest benefits,” says Anderson, who pegs the average cost of a workplace fall at $4,500. ❖ For more information: Nels Anderson, Ecolab Inc., 651-293-2233

6AN"UREN3Ts'RAND4ERRACE #! s4EL s&AX sWWWWILDENPUMPCOM Contact your Wilden authorized distributor today at www.wildendistributor.com

20


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Reimelt adds its world-renowned expertise to Zeppelin’s proud tradition of excellence

A world leader in the design, manufacture, and supply of highly automated and integrated materials handling systems for powders and liquids, Reimelt systems are installed in world-class food and beverage companies around the globe. Continuous dough mixing/kneading technology, frying systems, and fermentation systems complete our vast offering of food manufacturing solutions.

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

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Buhler Automation - traceable, tailored, transparent. The integrated automation solution WinCoS.r2 meets the highest food safety regulations in terms of product quality, traceability and production reliability. Based on industrial market leading systems, it combines process technology and automation at its best. The scalable and expandable Buhler brand is entirely tailored to U.S. market needs, not to mention the 24/7 support. Everything is under control, anytime and anywhere.

Buhler Inc., 13105 12th Ave N., Plymouth, MN 55441, 763-847-9900 [email protected], www.buhlergroup.com

Innovations for a better world.

FOOD SAFETY

A team approach to audits must be in place

`

Today’s audits are not only more complex, they are more comprehensive and demand a collaborative effort.

ost processors have teams within their organizations, such as production, quality, engineering, sanitation, shipping, receiving and purchasing. Audits have helped bring these groups together and get everyone “on the same page.” A few years ago, the only point man or woman for the sanitation or food safety audit was the quality assurance manager. He or she worked with the auditor, took him or her through the plant, and provided nearly all of the information. Today, audits are not only more complex, they are more comprehensive. Even though the quality Richard F. Stier, manager may still be Contributing Editor the point person, he or she must do much more. And that means making sure that every operating group understands its role, has documented procedures, maintains records and ensures that its staff has been trained on al l procedures pertaining to quality and safety. In addition, the quality manager must ensure each operating group is subject to internal audits conducted to ensure it is following established procedures. Doing the audits is not solely the responsibility of quality, however. The quality manager should be coordinating the program, but the auditors should include members from different operating groups. The key to proper internal audits is a trained cadre of internal auditors who are independent of the operations they are auditing. For example, production audits engineering; maintenance audits receiving; etc. When an internal audit or one conducted by a third party finds an issue, the plant must correct the problem and, if necessary, develop a program

M

to prevent it from occurring again. Corrective and preventive actions must be addressed by the operating group responsible for that area. The role of quality is to monitor that corrections are being made and verify that they have been implemented. Quality ensures that the loop is closed, but does not do the work themselves. The focus of third-party audits, especially those approved by the Global Food Safety Initiative, draw on the quality principles established by ISO 9000. Processors must: develop and implement procedures and work instructions; train employees on those protocols; maintain records that the work is being completed as written; review and verify these records; conduct audits to ensure protocols are being followed; initiate corrective and preventive actions when required; and work for continuous improvement. One method for doing this is a management review which brings together all operating groups on a regular schedule, with the primary goal of reviewing operations and developing improvement plans based on internal audits and other factors. Standardization of methods for developing, reviewing and approving procedures and work instructions is part of this equation. A few years back, many operating groups had their own procedures written in their own formats. Changes were made on whim or to make things easier, not based on risk assessment. Procedures and forms were often a mish-mash of different formats, old, new and outdated recordkeeping forms and variable recordkeeping practices. Today, most companies have a document control procedure that every operating group must follow. Now, the company is working as a team and not as individual entities. ❖


23

FOOD SAFETY

` U P DAT E

HEADSPACE SAMPLER

DAIRY COMPONENTS MEASUREMENT Advanced Instruments’ Delta Instruments LactoScope C3+/ C4+ analyzer for milk and cheese processors incorporates mid-infrared (MIR) technology, which is recognized worldwide by the IDF and AOAC as a standard method of analysis. The LactoScope’s MIR filter can measure specific bandwidths for the most commonly measured dairy components in milk. Through access to specific software applications, dairy processors using LactoScope C3+ can analyze fat, protein and total solids; with full C4+ software access, the capability to analyze lactose is added. A cheese application instrument can be used with the LactoScope to perform the same types of component analysis with cheese. Advanced Instruments; 800-225-4034; www.aicompanies.com

Agilent Technologies’ Model 7697A headspace sampler for gas chromatography (GC) sample analysis is based on the company’s automatic liquid sampler (ALS) technology, and features high performance without loss or degradation of volatile components found in the gas portion of partitioned GC samples. Headspace sampling allows the introduction of volatile compounds, from almost any matrix, directly into a GC or GC/ MS instrument. The technique is relatively simple when compared to other injection techniques, such as purge and trap, and keeps instruments cleaner than the standard liquid injection. The machine can be used for environmental applications, such as identifying volatile substances in water, flavor and fragrance profiling, and food safety testing, such as detecting volatiles in beer and other beverages. Agilent Technologies; 800-227-9770; www.agilent.com

“We spec Eriez’ feeders on all our systems”

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Easy Call. Big Payoff.

Save Energy. Save Money. Motorized equipment accounts for 64% of your plants electricity consumption every minute of every day. Your choices are to let your electricity bills continue to grow, or you can call in the Baldor Installed Base Evaluation Team and reduce your consumption fast. The Baldor IBE Team uses advanced data collection equipment and software to work with your plant maintenance personnel to take an accurate account of your motors and mechanical products, both in operation and from spare inventory. The IBE Team will produce

©2011 Baldor Electric Company

a comprehensive report and plan, targeting inefficient motors and mechanical drives with recommendations for immediate action as well as long-term strategies…all positively affecting your bottom line. If you’re ready to do something about your growing electricity consumption, email the Baldor IBE specialists at [email protected] or call (864) 281-2100 to receive case studies with realworld savings. It’s an easy call with a big payoff. baldor.com

FOOD SAFETY

` U P DAT E

GAS CHROMATOGRAPH

VISCOMETER FOR QC/QA

Shimadzu Scientific Instruments’ GCMS-QP2010 Ultra is capable of fast data measurement with sensitivity five times higher than previous models. The gas chromatography-mass spectrometry unit uses mass spectrometry technology called Advanced Scanning Speed Protocol (ASSP), a firmware protocol that optimizes the ion transmission hardware parameters with a highly efficient data collection algorithm to increase data acquisition speed up to 20,000 u/sec and 100 Hz. ASSP also provides the benefit of maintaining system sensitivity at elevated scan speeds. To help increase throughput, the instrument features high-speed oven cooling for shorter analysis cycles. Using a double-jet cooling system, the GC cools from 350º to 50ºC in less than three minutes. Shimadzu Scientific Instruments Inc; 800-477-1227; www.ssi.shimadzu.com

Perten Instruments’ RVA 4500 is a cooking/ stirring viscometer with ramped temperature and variable shear that can be used to determine the quality and processing characteristics of starch in grains, tubers, flours, and extruded and cooked foods and feeds. There are also applications for protein foods, ingredients such as modified starches and hydrocolloids, and malting and brewing. Perten Instruments; 217-585-9440; www.perten.com

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

And then we do it again. Inventing the new original since 1935. SABETHA, KANSAS USA

BELGIUM

USA TAIWAN

785-284-2133

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BRASIL

See Food Master, p. 132

26


CHINA

TURKEY

Calling All Sustainable Plants Food Engineering’s 3rd Annual Sustainable Plant of the Year Award Now is the time to prepare your entry for Food Engineering’s Sustainable Plant of the Year Award. This competition continues Food Engineering’s commitment to recognizing best-in-class manufacturing. The award will be presented to the most outstanding energy-efficient and sustainable food or beverage manufacturing plant project completed in North America during 2010. Submission Deadline is June 1, 2011. th Plant of stainable ing Co. u S 9 0 0 2 rew evada B Sierra N

e Year:

Enter your green plant project in Food Engineering’s Sustainable Plant of the Year Award competition today. Contact Joyce Fassl, Editor-in-Chief for entry forms and more information at 610-436-4220, Ext 8519 ([email protected]). Visit www.foodengineeringmag.com and click on Sustainable Plant of the Year call for entries.

e Year: lant of th P le b a stain g Co. 2010 Su m Brewin iu lg e B New

Presented by

TECHNOLOGY S O U R C E B O O K Focus on Extrusion and Pest Control

PASTEURIZATION SYSTEMS An alternative to gasses, radiation or carbon-producing thermal techniques, Radio Frequency Co. Macrowave Ultra-Series pasteurization systems apply a high-frequency electric field to control pathogens in food. Products are conveyed through the highfrequency electrode array where the alternating electrical energy causes them to heat rapidly and uniformly throughout their thickness; the food products are not exposed to elevated temperatures for long durations. The technology is “instant-on/instant-off,” using energy only during the treatment process. Radio Frequency Co., Inc.; www.radiofrequency.com

BIRD-DETERRENT LASER Recommended for use in processing plants, distribution centers, warehouses and loading docks, the Bird-X BLazer indoor-use bird-deterrent laser uses state-of-theart “fat beam” laser technology in dozens of constantly changing patterns to disrupt pigeons, sparrows, starlings, swallows and other birds. It covers up to 10,000 sq. ft. Bird-X Inc.; 800-662-5021; www.bird-x.com

LUBRICATION SYSTEM Designed for packaging, beverage processing, chain manufacturing and canmaking, the Spraying Systems AutoJet electrostatic lubrication system uses electrostatic nozzles to apply lubrication to ball bearings and other key areas of the chain. It sprays a negatively charged liquid that is attracted to the neutral, grounded target; the physical attraction of the liquid to the chain results in coating coverage. The system consists of a PLC and up to 4 low-flow injector pumps and 4 electrostatic spray nozzles. Spraying Systems Co.; 630-665-5000; www.spray.com

CONTAMINATION LAMP The Spectronics Spectroline B-260 battery-operated, long-wave UV lamp detects rodent contamination and aflatoxin on grains, feed, seeds and other crops used for human and animal consumption. When the lamp shines on rodent hair and urine, the hair fluoresces blue-white while the urine fluoresces blue-white to yellow-white. The unit is equipped with a 6V rechargeable battery, AC charger and charging cord. Enclosed in a high-impact plastic housing, the lamp features a stainless steel tube guard that protects against accidental breakage. Spectronics Corporation; 800-2748888; www.spectroline.com

COCKROACH CONTROL BASF SmartSolution for German cockroaches combines a range of products to overcome common cockroach treatment challenges. It contains baits, contact insecticides and residual insecticides including Prescription Treatment brand Alpine cockroach gel baits (reservoir and piston can), Avert dry flowable cockroach bait formula 1, Cy-Kick CS, Phantom pressurized insecticide and P.I. contact insecticide formula 1. BASF Corporation; www.basf.com


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TECHNOLOGY S O U R C E B O O K

TWIN-SCREW EXTRUDER Used in developing extruded food products, the Clextral Evolum 25 (EV25) twin-screw extruder also enables seamless transfer from R&D to full production. The extruder features a color touch screen control center that provides real-time operating data and facilitates immediate process changes for efficient R&D testing. Suitable for use with value-added products such as functional ingredients, whole grain foods, textured proteins, modified starches, multigrain breakfast cereals and snacks, and filled products, the unit has a variable frequency drive, independent temperature control and a push-button hydraulic barrel opening for process evaluation, screw profile changes and cleanout. Clextral Inc.; 813-854-4434; www.clextral.com

POLYURETHANE MORTAR SYSTEM Stonhard Stonclad G2 4-component, polyurethane mortar system incorporates post-industrial recycled glass and rapidly renewable materials. Resistant to thermal stresses, it is a seamless system, with no joints for dirt to build up in. Designed for areas where epoxies and urethanes traditionally do not perform well, such as kitchens, wineries and food processing areas, it omits low VOCs and contributes LEED points to MR6 and MR 4.1 and 4.2. It is available in 10 standard colors. Stonhard; 800-257-7953; www.stonhard.com

POSITIVE DISPLACEMENT PUMPS Watson-Marlow MasoSine SPS positive displacement pumps can pump large particulates while providing suction and consistent flow rates for marinated boneless poultry products. The pump mechanically spreads the product directly onto the conveyor; users can customize the extruded poultry product to the desired thickness for even cooking throughout the product. Watson-Marlow; 800-282-8823; www.watson-marlow.com



SANITARY V-BLENDERS Used for the dry blending of free-flowing solids, Ross sanitary V-blenders can handle solids that vary in bulk density and percentage of the total mixture. Materials being blended are constantly split and intermixed as the shell rotates. The blenders are supplied with intensifier bars for delumping and deagglomeration as needed. Discharge is accomplished through a manually operated butterfly valve positioned 24 in. from the floor when in the bottom position. The blenders are available in 5-, 10- and 15-cu.ft. sizes, and can be customized to include special discharge valves and other customer requirements. Charles Ross and Son Company; 800-243-ROSS

GHG FLOW METER Supporting EPA’s BACT (Best Available Control Technology) initiative, the FCI ST51 greenhouse gas flow meter measures and monitors industrial plant greenhouse gases per EPA requirements. It features a thermal mass, insertion-style flow element with flow accuracy to +/-1% of reading over a broad flow range from 0.3 to 400 SFPS (0.08 to 122 MPS), and repeatability of +/-0.5% of reading. The flow element is available for use in line sizes from 2 to 24 in., and operates over a turndown range of 100:1 and at temperatures from 0°F to 250°F. It withstands pressures up to 500psig [34 bar (g)]. Fluid Components International LLC; 800-854-1993; www.fluidcomponents.com

PICKER LINE Used with snacks, cookies or chocolates, the Schubert TLMF44 picker line picks up products from a belt and places them in packaging trays in a continuous operation. A mother tray is sealed in an upper film at the end of the line and then cut into portion trays. Stacking lugs stay in the web scrap, not in the trays. An MES system is included on the unit. Gerhard Schubert GmbH Verpackungsmaschinen; www.gerhard-schubert.de

Visit us at the AMI Show, Booth #2419 www.foodengineeringmag.com | Food Engineering | March 2011


KETTLE CHIP FRYER

HIGH-VOLUME DEPOSITORS Designed to operate with individual or strapped pans, the Hinds-Bock ring, layer and sheet cake fully automatic, highvolume depositing line is available in single or multiple lanes. Optional automation modules include a pan oiler, primary batter depositor or secondary depositor for swirled, layered batters or fillings such as fruit, cream cheese, mousse or chocolate. Hinds-Bock Corporation; www.hinds-bock.com

32


Using a thermal fluid heat exchanger, the Heat and Control MasterTherm kettle fryer delivers up to 80% thermal efficiency and over 500 finished lb./hr. of batch-fried potato chips. Standard features include continuous fines removal, electro-plated heat exchanger tubes, automatic slice agitation system, PLC control, full-length hood, clean-in-place system and stack oil mist eliminator. Single and multiple fryers are available with potato unloading, storage, washing and peeling equipment; slice feeders; de-oiling centrifuges; seasoning applicators; and conveying, inspection and packaging systems. Heat and Control, Inc.; www.heatandcontrol.com


GRATING HEADS Offering cuts from coarse granules to shreds, Urschel grating heads for cheese and bakery applications add flexibility to Urschel slicer/shredder Models CC, CC-D, CC-DL and CCX-D. The heads incorporate a design of 4 posts with corresponding fasteners, an upper support ring, locking lower support ring and grating screen. Optional interchangeable grating screens switch from one style to another. The heads can be used with cheese, coconut, nuts and carrots. Urschel; 219-464-4811; www.urschel.com

Hang up your gloves. A better way to wash and sanitize scale parts is right at your fingertips! Presenting the Douglas Model 1536-SPW. Meet today’s high standard for cleanliness and sanitation at the push of a button with this versatile, highly effective washing and sanitizing system. Installed in a pit or used with a ramp, this walk-in type batch washer cleans scale parts such as weigh and feed buckets, chutes, funnels, feed pans and other detachable items. This powerfully efficient machine also features pre-programmed wash times and a digital display that monitors key performance criteria and service requirements. And with a typical wash/rinse cycle of just 5 minutes, clean-up is quick and economical!

C ALL 800-331-6870 for pricing, literature and specifications on a model suited to your needs. 2101 C ALUMET ST. • C LEARWATER, FL 33765 • (727) 461-3477 (800) 331-6870 • FAX(727) 449-0029 • www.dougmac.com See Food Master, p. 54 www.foodengineeringmag.com | Food Engineering | March 2011

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LEVEL COMPENSATORS Piab lightweight LC series level compensators can handle sensitive goods with varying height requirements. They also allow an extra long stroke length to facilitate the handling of products with challenging geometries such as injection-moulded plastics, and provide shock and vibration absorption to protect other components in vacuum handling systems. The compensators work with the complete range of Piab fittings. Piab; www.piab.com

SAFETY & SECURITY in food and beverage facilities

Austin can assist you with your facility through:

Pre-Audit survey of processes and space Planning, scoping, and budgeting remedial actions Guidelines for capital project planning Criteria for design of processes and spaces Modernization and Migration Planning 3UHSDUDWLRQIRU64)$,%%5&FHUWL¿FDWLRQDQGPRUH Acknowledging the GFSI applicable guidelines

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

CONSULTANTS

34

DESIGNERS

INTEGRATED PROJECT DELIVERY ENGINEERS


CONSTRUCTORS

INDUSTRIAL VACUUM The VAC-U-MAX Model 860/02 industrial vacuum uses a VAC-U-MAX air-powered vacuum cover with manual pulse-jet filter cleaning and non-stick filtration to capture particles as small as 0.5 microns. The portable frame includes a collection hopper with an automatic discharge valve and polybag loading accessory. When the vacuum is turned off, the collected powder automatically discharges into an off-theshelf static-conductive polybag. VAC-U-MAX; www.vac-u-max.com

COMBINATION SCALE Designed for facilities that employ HACCP preventive principles, the CombiScale PrimoWeigher combination scale eliminates areas where biological hazards can reside. It has an uncluttered open-frame design, tool-less rotating center hopper, vibratory pans, buckets, and product and discharge chutes. Built with food-grade 304 stainless steel, the scale is available in 10-, 14-, 16-, 20- and 24-head configurations with 1.5-, 2.5- and 5-liter bucket sizes operating at speeds up to 80 to 200+ cycles/min. The electronics are centrally located in a remote-mounted electrical enclosure at eye level to assure their safety during washdowns. CombiScale Inc.; 305-895-8909; www.combiscale.com


AUGER FILLERS Featuring a tool-less hinged hopper, WeighPack Star Auger fillers come with a rubber gasket that eliminates product leakage and a quick-release design. Built with foodgrade stainless steel, the Star Auger 100 filler has a 23-qt. hopper with a fill range of 0.5 oz. to 1 lb. running at speeds up to 90cpm; the Star Auger 200 unit has a 45-qt. hopper and fill range of 1 oz. to 5 lbs. operating at speeds up to 70cpm. WeighPack Systems Inc.; 888-934-4472; www.weighpack.com

www.amerivap.com

The Moyno Max-Flow Annihilator grinder system protects downstream pumps, valves and process equipment in water treatment plants and their lift stations. The system contains 2 or more Annihilator grinders mounted side-by-side in a stainless steel retrieval frame. It includes guide rails to permit the independent retrieval of each grinder. Stainless steel or FRP control panels can be installed to control the operation of each grinder independently using manual or automated control systems. Moyno, Inc.; www.moyno.com

PH/ORP SENSOR A combination sensor including pH, ORP (Oxidation Reduction Potential) and temperature within the sensor body, the Emerson Rosemount Analytical Model 3900 general-purpose pH/ORP sensor is designed to measure aqueous solutions in pipelines, open tanks and ponds. It functions at sub-zero temperatures, providing accurate measurements in applications from -10ºC to 100ºC, and is equipped for both 3/4- and 1-in. mounting, allowing it to fit into smaller pipes. A Teflon doublejunction reference electrode protects the sensor from poisoning ions. The complete encapsulation of the sensor eliminates leakage and high-humidity problems. Emerson Process Management; www.emersonprocess.com

Steam Generator

Jet System

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

Brush System

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

JET SYSTEM

BRUSH SYSTEM

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

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

• • • • • •

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

First. . . Best . . . Different

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

GRINDER SYSTEM

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

AmeriVap® Systems, Inc. | Phone 404.350.0239 | Fax: 404.350.9214 Email: [email protected] See Food Master, p. 10 www.foodengineeringmag.com | Food Engineering | March 2011

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PORTABLE STORAGE RACK

ROTARY FEEDER VALVES

Keeping odd-shaped products organized and stored for shipping, the Steel King Pin Rack portable storage rack has adjustable 12-in. pin-type inserts and an array of holes in the bottom of the rack for users to insert the pins into in a configuration that conforms to the shapes being stored; it can also be used as an assembly rack for staging a variety of components required to complete one assembly. The rack’s tubular steel base acts as its own pallet. Racks can be stacked up to 10 high. Each can store up to 4,000 lbs. Steel King Industries, Inc.; 800-826-0203; www.steelking.com

Designed for rugged applications and the processing of harsh or abrasive materials, ACS CI Series rotary feeder valves have an outboard bearing design that manages applications with pressure differentials up to 15 PSIG, protects the bearings in applications up to 750ºF and removes the bearings from the path of damaging and contaminating materials. The valves are available in cast iron, 304 or 316 stainless steel, and sizes from 10 to 44 in. Rotor configurations include closed-end, metering, shallow-pocket, Teflon-coated and adjustable-tip. ACS Valves; 800-655-3447; acsvalves.com

MECHATRON® 3-A Loss-In-Weight Feeders

Quick, easy product changeover and food safety

SolidsFlow™ USDA Vibratory Feeders

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

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

36


Schenck AccuRate is a unit of Schenck Process

©2009 Schenck AccuRate


DIGITAL HYDRAULIC TESTER Compact and lightweight, the Omega HFP-110/120 digital hydraulic tester is self-contained and has laboratory accuracy. Designed for diagnostic troubleshooting of mobile or stationary hydraulic systems and components, it makes all flow pressure and temperature measurements simultaneously from one point. The CE-compliant tester features pressure relief disc protection and low battery/over-range indicators Omega Engineering, Inc.; 203-359-1660; www.omega.com

DUAL-BIN WASHER The Douglas Model BW-2000 dual-bin washer eliminates the need to buy 2 separate machines to double throughput; it washes and sanitizes 2 stainless steel or plastic bins at a time. The unit also reduces the incidence of injury normally associated with trying to hand wash these heavy containers. Douglas Machines Corp.; 800-331-6870; www.dougmac.com


37


Extruders. When it comes to Extruders we don’t mess around. We build the best. • Snacks • Cereals • Pasta • Low Shear • High Shear • Cooker Extruders DeFrancisci Machine Company LLC 500 North Drive Melbourne Florida 32934

SPIRAL CONVEYOR The Nercon live-drum spiral conveyor has a cylindrical drum that assists in driving the modular plastic belt; regardless of the conveyor length, the rotating stainless steel drum imparts the driving force to the inside edge of the belt, creating low tension on the belt throughout multiple tiers and allowing higher-elevation designs. The conveyor can be configured with various infeed and discharge locations, or engineered to lower or elevate products. It can also carry products between floors and machines or over aisles. It can transport jars, tubs, cups, bundles, cans, bottles, bags, pouches, cartons, totes and cases, and can accommodate several sizes of products on one production line without changeover. Nercon Engineering and Manufacturing; 920-233-3268; www.nercon.com

defranciscimachine.com [email protected] 321-952-6600

a compound bevel (two different bevel angles). The blades come in a variety of sizes including 5.86-, 6-, 7.188-, 10- and 10.63-in. diameters. Hyde Industrial Blade Solutions; 800872-4933; www.hydeblades.com

WEIGH BELT FEEDER

PROCESSING BLADES Engineered for smoother cuts through meat and poultry products, Hyde MeatMiser food processing blades have arcuates or “swooping teeth.” The arcuates enter the cut gently along the long arc without ripping into the food to be processed. Made of 420-grade stainless steel, the blades have a double bevel; and the bevel on each side has See Food Master, p. 49

The K-Tron Smart weigh belt feeder offers continuous online auto tare compensation by using 2 digital weigh modules. The first module measures the actual belt weight before receiving material, including the weight of material sticking to the belt. The second determines the gross weight after receiving material onto the belt. The feeder compensates for the difference. The feeder is available in 300 and 600mm belt widths. The SWB-300 model offers feed rates of 44 to 44,000 lb./hr. or 0.4 to 1,400 ft.3/hr.; the SWB600 unit is designed for feed rates of 88 to 88,000 lb./hr. or 0.7 to 2,800 ft.3/hr. K-Tron; www.ktron.com



For consistant food grade lubricant quality, buy from a company that is NSF H1 and ISO 21469 CERTIFIED.

HORIZONTAL MOTION CONVEYOR Suitable for fragile, seasoned, coated and frozen food products, the Key Horizon horizontal motion conveyor has a maintenance-free mechanical drive. Offering gentle and sanitary horizontal motion conveying, it is capable of moving product at speeds up to 42 ft./min. The conveyor’s horizontal motion produces a continuous self-cleaning action, preventing buildup of coatings, oil or seasonings as product slides along the pan; the sliding action prevents mixing and size separation of the product. The unit has stainless steel construction and limited flat surfaces. Key Technology, Inc.; www.key.net

Summit Industrial Products is one of the fast growing synthetic food grade lubricant manufacturing companies in the US.

Try us out and see why!

RE-WORK GRINDER Featuring a feed screw design with very low volume, the Mepaco Model 6-6RG rework grinder has a 3-bladed knife holder arrangement with 3 pressure flights to build the appropriate amount of back pressure to push usable meat through the unit’s 1/16-in. holes. Bone chips and connective tissue are effectively removed with minimal temperature rise through the bone collection assembly. An optional regulator bone valve removes a measured amount of materials from the grinder. Mepaco; 920-356-9900; www.mepaco.net

DEHUMIDIFIERS

ISO 9001:2008 KOSHER

Dehumidifying to low moisture levels, Munters HCD series desiccant dehumidifiers process between 300 and 12,000 CFM of air. Each unit casing is manufactured of fully welded, strain-hardened aluminum; the electrical control system meets UL and NEC standards. Standard units include all components and controls to operate as standalone dehumidifiers or can also be combined with other HVAC components. Munters Corporation; 800-843-5360; www.munters.us

HMI Available with an Ethernet expansion card, Red Lion Controls G3 Series operator interface HMIs allow users to add a second Ethernet port. The HMIs support 10 simultaneous Ethernet protocols and provide communication with devices on 2 distinct Ethernet networks simultaneously, without the use of an industrial router. The HMIs provide complete data logging, serial communications and remote monitoring. Red Lion Controls, Inc.; 717-767-6511; www.redlion.net


CFIA HALAL

800.749.5823 www.klsummit.com

SUMMIT

INDUSTRIAL PRODUCTS


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

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

LABEL PRINTER/APPLICATOR The FOX IV Technologies Model 5422 web print-and-apply labeler has a Uniwall design that mounts the Zebra 220 Xi4 printer components to an industrial center wall. The system has print speeds to 10ips, print widths from 4 to 8.5 in., label lengths to 14 in. and print resolutions of 203dpi or 300dpi; it comes standard with a 12-in. OD label supply roll. The system supports linear and 2-D bar codes, including Code 39, Datamatrix, PDF417, UCC/EAN Code 128 and UPC/EAN, as well as both direct thermal and thermal transfer printing technologies. Communication interfaces include RS232/422 and Ethernet. Wireless Ethernet is available as an option. FOX IV Technologies, Inc.; 877-436-2434; www.foxiv.com

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

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

MAGNETIC SEPARATOR The S+S Magbox Autoclean magnetic separator has magnet rods arranged in staggered vertical layers; each rod has an effective power of 12,000 Gauss for the separation of slightly magnetized stainless steel particles from the product flow. The separator features a rustproof, stainless steel, wear-resistant housing and a pre-programmed PLC controller with optional user interface. Cleaning is performed automatically by applying compressed air to the magnet cores that are transported to the cleaning area in their stainless steel casings. Some of the magnet rods always remain at their operating position during the cleaning cycle to guarantee separation of magnetic contaminants in continuous production processes. The unit complies with HACCP requirements and is certified according to ATEX zone 22 directives. S+S Separation and Sorting Technology GmbH; www.sesotec.com



STAINLESS STEEL MOTORS Resistant to high-pressure caustic solvents and cleaners utilized to help meet FDA bacteria and food contamination guidelines, Boston Gear stainless steel motors for harsh washdown environments have an exterior construction consisting of 300 Series stainless steel housing, end bells, output shaft and conduit box. UL/ULc certified and conforming to 2007 EISA efficiency standards, they have Class F insulation, Class B rise @1.15 service factor and epoxy-encapsulated windings. The 230/460VAC, 3 Phase, 60Hz (50Hz) motors are totally enclosed and available in 7 sizes from .5 to 3hp. Altra Industrial Motion; www.altramotion.com during braking. Standard features include AC motors, regenerative brakes and lowering system, and electronic steering. Crown Equipment Corporation; www.crown.com

5-AXIS ROBOT

REACH TRUCK Used in high-density warehouses and distribution centers, the Crown RM 6000 Series narrow aisle reach truck can reach 505 in. and deliver up to 1,000 lbs. more capacity at height; its forks travel upward at a speed up to 153 ft./min. The mast is offset 7 in. to the left of the operator and narrows the higher it goes. The reach carriage has a large window at eye level for a better view of the fork tips and load. A traction control system reduces tire spin during acceleration and prevents wheel lock-up

Engineered for food handling, picking, packing and other high-speed material handling processes, the Motoman 5-axis MPK2 robot with next-generation DXM100 can be used for applications with National Sanitation Foundation (NSF-H1) certified grease, and has an IP67 rating that permits washdowns, even with certain caustic chemicals. The robot features a hollow arm design that allows cables and hoses to be run internally throughout the entire robot from base to wrist; its slim arm design and internal cabling allow the robot to reach into confined spaces without interference. It has a 64-in. vertical reach, 35.4-in. horizontal reach, a top wrist speed of 2,000° per second and repeatability of +/-0.02 in. The robot can be floor-, ceiling- or wall-mounted. Motoman Robotics; www.motoman.com


’s

The Ritz-Carlton

APRIL 3-6, 2011 The Ritz-Carlton, Palm Beach, Florida

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

W Sunday, April 3

the need for better management of both human and equipment assets.

12:30 p.m.

Golf Tournament 3:00 – 5:30 p.m.

Registration 7:00 – 8:30 p.m.

Welcome Reception

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

Registration 7:00 – 8:00 a.m.

Continental Breakfast 8:00 – 8:10 a.m.

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

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

Theme for Day One: Continuous Improvement in Challenging Times 8:30 – 9:15 a.m.

Keynote Address: The Road to Manufacturing Innovation

GOLD SPONSORS

Keynote Speaker: Carlos del Sol, Vice President, Global Engineering Systems, Campbell Soup Company All food and beverage processors are searching for innovative practices to gain a competitive edge. In a constantly changing and challenging manufacturing environment, the speaker will address globalization, operational efficiency and

9:15 – 10:00 a.m.

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

and economic justifications for undertaking plant automation capital investments. Join your peers as they create best practices and recommendations for gaining approval on critical plant improvement projects. 12:00 – 1:30

Expo and Lunch 12:00 – 4:00 p.m.

Expo 1:00 – 4:00 p.m.

Solutions Theater 2:00 to 2:30 p.m.

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

Expo Reception 6:00 – 8:00 p.m.

Project Economics: Selling Plant Automation Improvements Moderator: Christopher Miller, Food Industry Consultant and Founder & CEO, Innovation Focus In this interactive session, audience members will collaborate on project cost analysis

Palm Beach Dinner

W Tuesday, April 5 7:30 a.m. – 1:00 p.m.

Registration

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

Tuesday, April 5th Track A 8:00 - 8:30 a.m. CDC Software 8:30 - 9:00 a.m. Atlas Copco 9:00-9:30 a.m. Siemens Industry, Inc. 9:30-10:00 a.m. Solarsoft Business Systems

Track B 8:00 - 8:30 a.m. Plex Systems 8:30 - 9:00 a.m. Clarion 9:00-9:30 a.m. Adept Technology 9:30 - 10:00 Beckhoff

Visit www.foodautomationconference.com for the latest Solutions Theater and program updates.

Register today and

SAVE $300!

Developed and Produced by:

w w w.FoodAutomationConference.com

QUESTIONS? Contact Marge Whalen, Senior Event Manager at 847-405-4071 or [email protected] 7:30 – 8:30 a.m.

1:45 to 2:30 p.m

Expo and Breakfast

Adapting to the New World of Food Safety at the Plant Level

8:00 – 10:00 a.m.

Solutions Theater 10:30 – 12:00 noon

Educational Tracks on State-of-the-Art Methodologies

Monkeiwicz

Palczewski

Kovach

Zelusky

Jeffries

Posada

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

Speaker: Greg Flickinger, Director of Manufacturing, Snyder’s-Lance, Inc. Driven by a rapid enhancement in scientific capability, the paradigm in many Consumer Packaged Goods facilities has rapidly changed from a visibly clean standard to a microbiologically clean expectation. Ingredients once deemed low risk have quickly become higher risk. Processes and procedures considered effective are now viewed as inadequate. This combined with imminent governance and regulation has created an environment where production plants must change not only processes and procedures, but culture overnight. This session will focus on the process of transforming culture to keep pace with the new reality of food safety. 3:00 to 3:45 p.m.

Sanitary Design of Equipment: What You Should Know Speaker: Al Koch, Director of Engineering, Global Biscuit, Kraft Foods Nabisco Division Recalls and food contamination can be avoided by implementing state-of-the-art sanitary design standards. This session will present practical and pertinent information from food manufacturing leading user groups such as AMI (American Meat Institute) and BEMA (Baking Equipment Manufacturers and Allieds). 3:45 to 4:30 p.m.

Plant of the Year Award Join us as we honor the 2011 Food Engineering Plant of the Year award winner. Each year, only one food or beverage plant in North America earns this award. 4:30 to 6:00 p.m.

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

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

Plant of the Year Celebration Cocktail Reception Dinner: On Your Own

W Wednesday, April 6 Theme: Sustainable Plant and Process Practices 7:00 – 8:00 a.m.

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

Building and Maintaining Success in Energy Conservation Speaker: Daniel Fonner, Senior Manager, Global Utilities, Heinz North America

SILVER SPONSORS

12:00 to 1:00 p.m.

The enthusiasm for sustainable manufacturing practices can sometimes be squashed by energy initiatives with high up-front costs. This speaker will focus on overlooked opportunities with solid paybacks. 9:00 – 9:45 a.m.

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

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

Maximizing Sustainability Benefits While Managing Wastewater Challenges Speaker: Peter Takacs, Manager, Quality Assurance, Spoetzl BreweryBreweries and other food and beverage processors frequently face wastewater challenges that threaten not only their regulatory requirements but also their relationships with local municipalities or water utilities. At the same time, identifying cost-friendly projects that help meet sustainability goals remains a focus. This session will describe one brewery’s wastewater challenges, the rationale behind the environmentallypositive path chosen, and the output and expected on an ongoing basis. 12:00 noon

Conference Adjourns

Food Safety Audits

Meeting the CertiÀcation Challenge Head On

44

February 2009 | Food Engineering | www.foodengineeringmag.com

Certification programs under the GFSI umbrella are taking root in North America, though not without some growing pains and process changes for food manufacturers. ` Kevin T. Higgins, Senior Editor

A

lthough an out-of-control oil spill trumped food recalls as 2010’s top disaster, food safety was front and center for both the food industry and the public. ASSET MANAGEMENT Even in a gridlocked Congress, the Food Safety Modernization Act (FSMA) mustered enough yea votes to pass both houses and land on President Obama’s desk. The almost complete lack of opposition sealed the legislation’s approval: Cognizant of the damage recalls have done to the entire industry’s image in recent years and the erosion of public confidence, major brand owners supported passage. Those same brand owners, either overtly or tacitly, have also thrown their support behind the certified audit programs under the Global Food Safety Initiative (GFSI) umbrella. The time and additional expense of these intensive inspections and systems reviews are offset not only by improved customer relations with key accounts but also the brand owners’ desire to push the standards out to their own suppliers. The 2009 salmonella recall involving peanut butter and peanut paste from Peanut Corporation of America ensnared more than 2,100 products from 210 food companies. It served as both a wakeup call and a stark reminder that a company’s products are only as safe as the weakest link in the supply chain allows them to be. “A lot of what has been done in the past with third-party audits was deficient,” confides a facility manager at one food company that underwent SQF certifications at its facilities last year. “What has been done has not nearly been rigorous enough.” GFSI’s roots are in Europe, where retailers led the charge for standardized audits such as BRC, created in 1998 by the British Retail Consortium. To bring consistency to the independent reviews, GFSI created a benchmarking system to ensure requirements for prerequisite programs, HACCP planning and execution, and the food safety management system were consistent between the various standards. Several audit programs are geared to food and beverage manufacturers. By far, the largest in North America is SQF 2000, managed by the Food Marketing

Institute’s Safe Quality Food Institute, with BRC gaining traction. Manufacturers also can be audited under the International Food Standard (IFS) and FSSC 22000. Other GFSI-sanctioned programs are geared toward agricultural operations or have not been extended to North American manufacturers. “If it isn’t written down, it didn’t happen” is a guiding principle of all the standards, and documenting the execution of good manufacturing practices (GMPs) and staff training is perhaps the most challenging aspect of the audit programs. Upfront documentation work stretches out the timeline for GFSI reviews, “but the true test of how long it’s going to take is management commitment and resource allocation” to the process, according to Robert Prevendar, director of food safety certification systems at Ann Arbor, MI-based NSF International Inc. Prevendar suggests food manufacturers budget five months to complete a GFSI certification process, though he allows, “Five months is optimistic. It’s achievable, but it’s almost a bare minimum.” In fact, a year may be a more realistic timeline. As a USDA-inspected plant with organic and gluten-free certifications, Kettle Cuisine knows the audit drill well, yet its quest for SQF level 2 certification stretched over 12 months. “SQF changed the responsibility from a QA function to a production program,” says Karen BishopCarbone, director of quality assurance at the Chelsea, MA maker of soups sold primarily through supermarkets’ grab-and-go prepared meal programs. Food safety requires top-down management, but an effective program requires bottom-up execution, and Kettle Cuisine invested considerable time training a bilingual staff that peaks at 150 workers to assume an expanded role in executing and recording quality and safety checks. A letter from a retail customer triggered Kettle Cuisine’s SQF quest. John Corsos, president of Coastal Sunbelt Produce Co., Hanover, MD, didn’t wait for inquiries from food service accounts to begin the SQF process, which also took his company a full year. “We had very robust documentation going in,” says Corsos, and participation in USDA’s Quality through Verification (QTV) provided a solid founwww.foodengineeringmag.com | Food Engineering | March 2011

45

FOOD SAFETY AUDITS

` Most food plant workers are indoctrinated in the principles of safe food handling, but companies seeking certification under one of the GFSI programs are augmenting it with intensive training that allows them to assume duties typically assigned to quality assurance staffers. Source: Martin Putney, AIB International.

dation. But there are no shortcuts in a certification system that “brought in a different approach,” he says. Electronic record-keeping facilitated documentation requirements and helped Shearer’s Foods Inc. attain SQF Level 3 certification for its Massillon, OH plant in two and a half months, according to Don Asplin, corporate director of food safety. Salty snacks with low pH and minimal water activity are low-risk foods, but management commitment and a company focus on quality, compliance and record management drove Shearer’s fast-track certification process. “Either people want to do food safety and quality, or they’re going to cut corners,” says Asplin. Core programs such as pest control are executed in house and are subject to self-audits and continuous improvement to ensure no corners are cut. A broken system? The case for more rigorous and consistent third-party audits was bolstered by an existing audit system that

bore a certain Lake Wobegon quality, where virtually every production facility was judged to be above average. The PCA plant at the center of the 2009 recalls was certified as superior under third-party audits. GFSI proponents seized on the PCA event to advocate for a system that addressed perceived deficiencies, such as requirements that nonconformance issues cited in audits be corrected prior to certification, and institution of arm’s length rules to minimize conflicts of interest that arise when auditors also offer advice and counsel to food manufacturers. Some see a parallel between the get-tough approach of the GFSI standards and a more aggressive regulatory stance. FSMA gives public health agencies the power to conduct unannounced inspections, demand access to documents and, for the first time, require a HACCP plan for all food manufacturing facilities. Independent auditors won’t be making surprise inspections, but they will hold plants to FSMA requirements, says Thomas Carl Ambrosia,

Whose scheme is it, anyway? Britain and America are separated by a common language, it is said, and that disconnect is illustrated in the Global Food Safety Initiative’s (GFSI) vernacular for the food safety audit standards under the GFSI umbrella. GFSI’s roots are in Europe, and the organization defers to the Brits for English nomenclature. Consequently, the certification programs benchmarked by GFSI bear the unfortunate name “schemes.” To an American ear, it raises suspicion; from an American mouth, it sounds like an affectation. Regardless of the term programs or schemes, the owners of the half-dozen standards approved for use by food manufacturers oversee audits that have been harmonized to include consistent expectations while allowing for minor differences in execution. The management of those standards—SQF 2000, BRC, FSSC 22000, IFS, Synergy 22000 and Dutch HACCP—must meet the requirements of the American National Standards Institute (ANSI) in the United States.

46


The accreditation bodies overseeing those standards (for example, the Safe Quality Food Institute in the case of SQF) act as brand owners who ensure the integrity of their programs. The groups train and certify auditors to their standards, but they rely on certification bodies (CBs) to hire and supervise certified auditors. Certification bodies include NSF International (formerly Cook and Thurber), Silliker Inc., AIB International and a number of CBs that have become active in US food safety audits in recent years, including Eagle Food Registrations, Det Norske Veritas and TUV SUD America. Certified auditors are the boots on the ground. Once they have satisfied the requirements of the licensing program, they are free to perform audits for any of the CBs, though some choose to work for one CB exclusively. Annual performance reviews, refresher courses and licensing fees are required, just as food plants must be recertified at least annually.

Bottlers, Achieve Food Safety & Quality Objectives NSF International is the leading certifier to GFSI* benchmarked standards. Beyond food safety systems, we also deliver the only ANSI accredited Product Certification through verification and testing that demonstrates industry excellence. Only one certifier gives you both the food safety and product certification to meet your customers’ needs through… 65 years of food safety and certification experience technical expertise in all food sector categories food safety and quality systems training programs a worldwide network of established auditors and operational capacity to get your audit done to meet your timelines! Choose the food safety expert that can add value to your food safety and quality systems.

®

Contact Ed Logan today for a free assessment to determine how ready your facility is to achieve certification. Email [email protected] or call +1-734-827-5624.

NSF International 789 N. Dixboro Road Ann Arbor, MI 48105 www.nsf.org | +1-800-NSF-Mark * The Global Food Safety Initiative (GFSI), an independent non-profit foundation managed by The Consumer Goods Forum, was founded in 2000. © 2011 NSF International

FOOD SAFETY AUDITS

` Processors like Coastal Sunbelt Produce not only must document their own procedures but also verify the procedures of their suppliers. Source: Coastal Sunbelt Produce Co.

an auditor for the certification body (CB) TUV SUD America, Peabody, MA. “Third-party auditors are now miniature USDA inspectors,” says Ambrosia, who has performed food safety audits for 35 years and is certified under all 35 SQF product categories. Others see the emphasis on manufacturing site audits as the first salvo in an effort to bring greater accountability and transparency to the entire supply chain. They see parallels with industries such as medical supplies, where it is not enough for a packaging supplier to be ISO certified: The suppliers of resins and other materials to the supplier also must be certified. “The back-end supply chain is where the

problems often lie,” points out Katie Dowling, senior solutions consultant at Sparta Systems, Holmdel, NJ. “When there’s a problem with a company’s granola bar, it’s not the granola bar but the ingredients that came from outside the plant and went into the bar.” Dowling’s firm provides quality management software that maintains a rolling schedule of audits and generates documentation reports, including any nonconformance issues and the corrective actions taken. The level of detail in supporting documents goes well beyond what has been customary. “If you operate a fryer for breaded meats, you need to document the oil coming in, the waste stream of crumbs removed from that oil, where the rework and work in process comes out, and other parts of the entire process,” suggests John Surak, principal of Surak and Associates, Clemson, SC. He was one of three US representatives on the ISO technical committee that drafted ISO 22000. The standard serves as a framework for a food safety management system but was deemed insufficient by GFSI as a food safety standard. The deficiency was addressed with PAS 220, a GMP-oriented standard developed by Kraft, Nestlé and others. The certification program offered by FSSC 22000 combines PAS 220 and ISO 22000. Surak is certified by the International HACCP Alliance and the American Society of Quality to train HACCP trainers and conduct quality audits. He cannot conduct any of the GFSI audits, though he can consult with manufacturers working toward certification. That kind of arm’s length relationship is encouraged by all, and required by some, of the audit programs. “If I am going to be your auditor, I cannot consult or train,” TUV

The birth of independent audits Until an E. coli O157:H7 outbreak in 1993 sickened 700, including four fatalities among children, third-party independent audits of food plants were almost unheard of events. The outbreak was linked to the Jack in the Box (JIB) chain, which responded by hiring David Theno to implement a HACCPbased food safety management system for its restaurants and demand that key suppliers open their plants and their records for inspection. Now retired from JIB but still active in the Del Mar, CA consultancy Gray Dog Partners, Theno believes customer demands for continuous improvement in food safety have resulted in positive change. Few manufacturers in the early 1990s had HACCP plans, and the ones that existed were little more than checklists. Today, leading manufacturers “have turned food safety from a chore into a management program,” he says.

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Owners of the certification programs under GFSI suggest gaining plant certification will help reduce the number of audits performed, with some retailers promising to accept any of the GFSI reviews. It’s a comforting thought, Theno concedes, but he is among many skeptics. If he still were responsible for a food service or retail operation, Theno says he would insist on sending inspectors to suppliers’ plants to assure all product attributes and specifications are being met. But he empathizes with plant personnel who must cope with a growing number of audits and inspections. “One plant operator told me, ‘I’ve added a staff person to serve as a tour guide,’ and that’s not productive,” says Theno. He also is concerned that details and procedures required are adding unnecessary complexity that might degrade the effectiveness of a food safety program.

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FOOD SAFETY AUDITS ` Good manufacturing practices by front-line workers are prerequisites to a successful third-party audit under the Global Food Safety Initiative. Source: Coastal Sunbelt Produce Co.

SUD’s Ambrosia says. “I’m not supposed to cut you a break. The code of ethics says my allegiance must be to the standard, not the CB or the customer.” Laying the groundwork GFSI-sanctioned audits require an approach to food safety that is unfamiliar to most food professionals, including many in the food safety/quality management area. Lacking the inhouse expertise to navigate the system, companies frequently

retain consultants to conduct pre-audits and assist in gap analysis of existing programs and the certification requirements. Costs vary, but one auditor estimated food companies typically spend $20,000, including $5,000 for the certification audit itself. Approximately one in 10 companies that begin the process does not complete it. In some cases, self-assessment lays bare facility deficiencies that require capital spending to correct. “Some companies hire us to put what they already know in a nice-looking report they can present to management for capital spending approval,” says Charles Caban, senior process engineer for the Atlanta A/E firm The Austin Company. “Sometimes, going into the job we know that it would cost more to update the old facility than to build a new one. “Capital money has been under tight reins the last couple of years,” Caban adds, and necessary improvements to a ventilation system or other infrastructure projects can quickly torpedo the certification process. More frequent reasons for failure to attain certification include a lack of management commitment or the delegation of too much responsibility to safety directors and insufficient involvement of other staff.

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FOOD SAFETY AUDITS ` Certified auditors consider food waste on the production floor a deficiency. Simply removing it is not enough, food professionals say; personnel should document the removal.

“Management commitment is a fundamental requirement, but you also must involve the people on the line, the maintenance department and every area involved in handling the product,” asserts NSF’s Prevendar. “Time is involved, and time is always connected to finances,” remarks Kettle Cuisine’s Bishop-Carbone. “We saw an impact in payroll, we saw it in facilities management, we saw it in IT.” Time and expense were viewed as an investment, she adds, and recommendations by a consultant who performed a pre-audit proved valuable in adjusting policies that conflicted with aspects of the certification program.

Before deciding which certification to pursue, manufacturers first should ask their key customers what their preferences are, recommends James Cook, food safety technologist in the Fairfield, NJ offices of SGS Group, a CB with auditors certified under most of the programs. Once the best alignment with customer requirements and the company’s existing food safety system is determined, a copy of the standards and the guidance document should be purchased. Scheduling a certification audit is premature until documentation issues and gap analyses are performed. Documentation detail is often a stumbling block: Kettle Cuisine regularly administers food safety quizzes to workers, Bishop-Carbone says, but auditors expect documentation of when those quizzes are administered, what issues were uncovered, and what corrective actions were taken. “It took me 10 months to get a USDA-inspected company up and running and confident it would pass the certification audit,” says Cook. “The documentation part took six months.” Boots on the ground Estimates of the number of US food plants that have successfully completed one of the GFSI audits range from 3,000 to 3,500, a

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fraction of the plants currently providing processed foods to retailers and food service accounts. Estimates of the country’s production base vary significantly. More than 150,000 sites are registered with the FDA , though that figure undoubtedly includes distribution facilities

and farm-level operations. Maureen Olewnik, vice president-audit & technical services at AIB International, Manhattan, KS, believes the manufacturing base is closer to 30,000. A census of US food and beverage plants published by Food Engineering in 1998, listed approximately 17,000 facilities.

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These figures suggest at least 80 to 90 percent of food plants have yet to undergo a GFSI audit. If the GFSI programs are to become America’s food safety standard, recruitment and training of qualified auditors will have to be expanded significantly. SQF has the largest pool of certified food safety auditors, with more than 300, according to Bob Garfield, SQF senior vice president, and it has more auditors than the other standards programs combined. “ You would need 30,000 auditors to cover the entire US market,” Ambrosia believes. Wary of diluting the auditor base or compromising their brands, standards owners used to tightly control the training opportunities for aspiring auditors. That is beginning to change. According to Garfield, SQF is allowing some of its CBs to train their own auditors to conduct SQF audits, rather than requiring all auditors to be trained by SQF personnel. Those CBs must first be approved by SQF and are subject to monitoring. Of the 20 CBs certified under SQF’s program, five are allowed to conduct auditor training. “People who have reached retirement age or whose plants were shut down” represent the best talent pool to fill the auditor ranks, suggests Roger Roeth, food and training manager at Dayton, OH-based Eagle Food Registrations Inc. “Unfortunately, you’re not going to get young people right out of college,” given the requirement for five or more years’ experience in food production for most of the programs. Travel requirements can be grueling, though compensation is attractive, with certified auditors typically commanding $50 or more an hour. The fastest growing segment of Eagle’s business is not at food or beverage plants but at the facilities of packaging suppliers and warehouses and distribution centers. That reflects the outward push from customers like McDonald’s and Walmart. The Bentonville, AR chain required private-label suppliers to be GFSI certified two years ago, while suppliers of branded

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food products faced a 2010 deadline for certification. As a practical matter, retailers and food service customers are focusing on suppliers of higher-risk products. “Make no mistake: The intention is to bring in many or most of their suppliers under GFSI,” according to Ron Vail, an auditor trainer at AIB.

Absent an adequate infrastructure, GFSI requirements could go the way of Walmart’s RFID mandate. The retailer set a January 2006 deadline for RFID tags on all pallets and cases of products bound for three Walmart DCs, but the mandate was abandoned. To require RFID would have meant many empty shelves and unhappy shoppers.

AIB’s Olewnik believes the GFSI system will overcome its growing pains and become firmly established in the food manufacturing community. GMP audits remain the most frequently performed reviews conducted by AIB’s 120 auditors, who perform more than 10,000 plant reviews a year worldwide, “but we are seeing a growing trend on the GFSI side, and we think that will become the norm,” she says. The establishment of a two-tier system, with some food manufacturers eschewing certification and supplying customers who don’t require it, is a possibility, or an alternative to the GFSI approach could evolve. “There may be companies unable or unwilling to keep up with the standards,” points out Coastal Sunbelt’s Corsos. Whether the majority of food suppliers accept the expense of certification audits doesn’t concern him. “We’ve been laser-focused on delivering quality to our customers, and our emphasis on food safety and process improvement has separated us from the pack,” he says. Until a critical mass of production facilities attains certification, customers will have to temper their GFSI requirements. In the meantime, food professionals will wrestle with the requirements of a new system requiring a different approach to food safety. ❖ For more information: Maureen Olewnik, AIB International, 785-537-4750, [email protected] Charles Caban, The Austin Co., 770-329-0089, charles.caban@the austin.com Roger Roeth, Eagle Food Registrations Inc., 937-293-2000, [email protected] Robert Prevendar, NSF International Inc., 734-769-8010 Bob Garfield, Safe Quality Food Institute, 202-230-0635 James Cook, SGS Group, 973-461-1493, [email protected] Katie Dowling, Sparta Systems, 732-203-0400 John Surak, Surak and Associates, 864-654-8743, [email protected] Thomas Carl Ambrosia, TUV SUD America Inc., 570-925-2614, [email protected]

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SENSORS ` T & D Corporation’s Model RTR500AW wireless LAN-connected data collector works with the company’s data loggers and remote units to download readings over a 900 MHz wireless link and then present the data over a network through an 802.11g Wi-Fi connection. Source: T & D Corp.

Make the Right Choice with Wireless Smart Sensors Smart sensors have been around for a long time, but when combined with wireless capabilities, the sky’s the limit. ` Wayne Labs, Senior Technical Editor

I

f you are anticipating a wireless future, you can easily spend $6,000 or more for an intelligent sensor capable of preventing and withstanding an explosion, but you probably don’t need to spend that much. Instead you can choose from self-contained wireless sensors/ transmitters or use wireless RTU (remote terminal unit) and I/O units with a cluster of wired sensors that will tie into the plant network through a gateway device. To have a successful and upgradeable wireless installation, however, you need to know what you want to accomplish, as well as how much your needs will grow.

With the ISA100.11a specifications complete, processors can choose from new ISA100-compatible sensors and gateways or several already existing WirelessHART devices on the market—from low-cost, “hockey-puck” sensors right on up to the $6,000-plus explosion-proof sensor. In addition, several alternative proprietary solutions are available with price tags ranging from a couple hundred dollars for a temperature node to about $2,000 a point for some RTU and remote I/O-based units that let users cluster wired sensors together for transmitting to a remote data collection unit or Ethernet gateway. The new ISA100.11a specification


59

SENSORS

` In keeping control systems separate, delivering information directly to IT applications may provide a more cost-effective alternative (e.g., initial outlay, lifecycle costs) for some monitoring applications (i.e., environmental, energy, supply chain, reliability improvement, device lifecycle management, etc.). A direct connection eliminates the need for traditional hardware components and software systems. Source: Endress+Hauser.

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allows for WirelessHART and other protocols (e.g., Modbus TCP) to be “tunneled” through its system components, giving users the option of using these with ISA100-compatible equipment. If you are planning an intelligent, wireless sensor network, there are some important considerations above and beyond radio frequency (RF) communications theory. This article looks at some of the practical issues in choosing a wireless sensor network. While cellular technology is a long-haul technology supported by several wireless sensor suppliers, it is not covered in this article. Should you need the longer coverage cellular systems provide without an investment in licensed-radio technologies, be sure to ask your sensor/automation supplier about this option. Cases for wireless In some ways, it might be counterintuitive to think wireless sensor networks could provide better solutions than wired networks when interference is an issue. For instance, Craig McIntyre, Endress+Hauser chemical industry manager, relates a story about a wired network at a brewery near Heathrow Airport. As is the case with shielded cables, this Profibusbased wired network could not be grounded at all locations because of ground-loop, induced noise. When the new sensor network was brought online, sensor signals were skewed if not totally unusable. Upon further investigation, sensor network engineers found the radar system at Heathrow was interfering with low-level sensor signals. Some additional network cable grounding procedures solved the problem. While a wireless network is not com-


pletely free of interference, in this case, it might have been a better solution. Wireless sensors can overcome the limitations of wired devices in rotating machinery. Kaitlin Carter, Banner Engineering marketing analyst for wireless products, tells the story of a bottling plant that tried using a level sensor with a signal that passed through slip rings on a rotating filler. Getting a usable signal proved to be a maintenance headache, so the bottler’s engineers installed a wireless node on the rotating machine, and now the system receives a noise-free signal from the level sensor. Several wireless opportunities exist in a plant or warehouse. For example, if it’s too long a distance to be practical for a cable, or if infrastructure has to be torn up and replaced to route a cable to a sensor on a tank or silo, a single wireless sensor used in conjunction with a wireless gateway attached to the plant network may offer a complete solution. However, if the distance between the two is a little too long, or if there are obstructions in the path of the signal, there are a couple of options. First, mesh networks use multiple sensors, each with a radio transmit-receive capability and the ability to relay signals from one to the other. Second, point-to-point configurations using a single or multiple sensors can have their range extended with the use of repeaters— devices dedicated to retransmitting the signal. Mesh sensor networks If a manufacturing plant needs to measure additional process variable points that are located between the first wireless sensor and gateway, further wireless sensors that support a mesh network could be employed. According to Gareth Johnston, ABB’s global wireless product manager, WirelessHART sensors have built-in mesh networking and can support the range and robustness expected for process applications. In a mesh network, each sensor can act as an intelligent repeater, so if the first path isn’t reliable enough to pass the signal, the network will reroute the signal to the gateway using the optimal number of wireless sensors in between as repeaters. In a mesh configuration, three or more wireless sensors will get the signal to the gateway.

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` Point-to-point wireless was used at Coca-Cola’s Dasani Water facility in southern Missouri. The network connects three wells in the Roubidoux Formation before relaying data to the bottling plant. Source: Opto 22.

62

Processors with Emerson Process HART-based wired sensors in place and close enough to form a mesh network can convert the sensors to wireless operation for the incremental cost of an add-on WirelessHART adapter. This is helpful when there is nothing wrong with the sensor, but the wiring has seen better days. Rather than pull or change old wiring, the maintenance crew can attach Emerson’s SmartWireless THUM adapter and put the sensors on a WirelessHart mesh network. This device also lets processors gain access to advanced diagnostics for remotely managing devices and monitoring their health. The THUM technology was recently added to Rosemount’s tank gauging systems, and in the first field installation of these systems, all are operating successfully, says Mikael Inglund, Rosemount technical product manager. “All those tanks had power cabling but no proper signal wiring, so the customers saw significant cost savings by not having to do new cabling work.” Mesh sensor networks are suitable for applications where redundancy is more important than transmission speed and data rates, says Dan Dudici, Invensys Operations Management business development manager. When speed and data rates are more important, he recommends choosing a point-to-point solution such as the Invensys WiModPak wireless I/O solution, which provides low latency (about 25 ms) and data rates of 250 kbps using proprietary, optimized technology. Because of the latency of wireless systems, food processors use industrial wireless equipment pri-


marily for monitoring and data gathering and, in most cases, aren’t ready to trust a wireless system to run any controls—at least critical ones. The lack of determinism in a mesh network does not lend itself to control when the network may spend time reorganizing and rerouting signals, says Russ Graybill, Yokogawa general manager of network solutions. In many cases, mesh topology is overkill and adds more complexity than necessary. When sensors aren’t being moved from one location to another, it makes more sense to use point-topoint routing, adds Graybill. To anticipate the needs of its users, he says Yokogawa lets customers turn off mesh protocols and use fixed routing in its mesh products. The redundancy of a mesh network might be what users value most—so much that some mesh network users think network redundancy and reliability are better than their wired networks, says McIntyre. With the builtin redundancy of WirelessHART and ISA100 protocols, users not only get the process variable from the sensor, but also information about the network’s health—like the signal indicator on a cell phone. But when a wire breaks on a sensor network, users may have little information to know where the break is and how the network is affected, he adds. Point-to-point solution If the cost of mesh-capable wireless sensors is an issue, and more than one or several process variables need to be measured at a single site, a good, less-expensive alternative might be to aggregate all the sensor data into a compact, local, programmable automation controller (PAC), I/O system or other device with the capability to communicate over Wi-Fi, says Ben Orchard, Opto 22 application engineer. There are two advantages to this method. First, wireless Ethernet equipment usually has better range than discrete wireless sensors, and second, wired sensors provide users with a wider range of devices—and are more affordable as well. Should the Wi-Fi option become a little challenging because of distance, processors can add repeaters between endpoints—such as data collectors and loggers and gateways. “Nominal range between our [wireless] loggers and data collectors

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SENSORS ` The THUM adapter module can be installed on existing Emerson HART field instruments to free up diagnostics and process information that was previously inaccessible under typical wiring architectures. This diagram shows Emerson’s Rosemount TankRadar Rex tank gauging system in a WirelessHART mesh network. Source: Emerson.

is about 500 ft., line of sight,” says Steve Knugh, T & D Corp. factory representative. Because coverage can be affected by intervening structures, he recommends the use of a wireless repeater to extend the range, or daisy-chaining wireless repeaters to extend the distance even farther. Temperature monitoring is critical in the regulated industries, and often a point-to-point wireless system can do the job inexpensively and in a timely manner. Ashish Desai, Omega Engineering application engineer, has seen wireless RTDbased (resistant temperature detector) sensors used in some pharma company freezers. In this application, temperature data is passed to a central alarm system that alerts the maintenance crew as soon as there is a trend in the wrong direction. Other point-to-point applications include tank level monitoring and temperature monitoring inside greenhouses and seed storage units. Users can start out with an industrially packaged sensor (thermocouple [T/C], RTD, RH, pH, process voltage/ current) and a receiver (IP68 packaging if needed) capable 64


of working with 48 wireless sensors. The receivers come with software supporting Oracle databases and Excel spreadsheets, and can connect to a PLC or data acquisition interface. One automated HACCP solution provider in the UK makes use of wireless temperature monitoring, providing time-stamped temperature data logging for small food processors, freezers and retailers. The records satisfy regulators that correct temperatures have been met and held. The Kelsius HACCP solution is paperless and records air and product temperatures in all refrigerated areas. “In dealing with food safety, the system has to be paperless, more efficient and less labor-intensive,” says John Ireland, fresh food manager for the Gala Group. According to Ireland, the system also eliminates the risk of human error during the food preparation process. It’s often difficult to track where sensors are being used, but Knugh points to popular applications for wireless sensor networks including monitoring the storage condition of certain areas in refrigerated/frozen warehouses where specific areas (microclimates) present varying temperature requirements. Loading dock temperatures are also important, and these wireless systems provide electronic records with time stamps that meet 21 CFR Part 11 requirements. Other key applications include a deli/meats processor that monitors the cooking temperatures of prepared meals and a cheese manufacturer that continuously monitors its process temperatures. One food processor in the Northeastern US that wanted to monitor several batches decided to use wireless sensors whose data wound up at an electronic chart recorder. Because sensors were always being moved as changes were made to the process, the manufacturer opted to use wireless T/Cs, which transmitted to a wireless gateway connected to the chart recorder through the plant network, says Graybill. With all the location changes of the sensors, putting in fixed, wired sensors wasn’t practical. Wireless controls Though several suppliers sell wireless hardware (Opto 22 included), most customers are not yet comfortable with doing control wirelessly, says Orchard. For industrial control in food processing applications, wireless control isn’t fast or deterministic enough to satisfy the needs of packaging, slicing, bottling and other high-speed applications, though it may be fine for longer-running batch process operations where sensor data is transmitted at the seconds rate (as opposed to micro- and milliseconds). Faster sensor update rates will always have a higher price tag, says Dudici, so the practicality of using wireless for both

SENSORS ` This small DC-to-DC power supply works as an interface between thermoelectric converters and EnOcean transmitreceive modules. Using heat to produce power for wireless sensors allows for operation without concern for replacing batteries. Source: EnOcean.

sensing and control will most likely be out of the budget compared to wired systems. But prices will come down as new technologies are developed, standards are in place, and competition intensifies. Trials are underway to prove a wireless network can support PID control, says Johnston. WirelessHart has been designed with PID control in mind and adds a time stamp to process data, which can be used in a modified algorithm to account for message delays, he states.

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Whether or not controls can be connected wirelessly, maintaining a separation strategy has its advantages, says McIntyre. “A field device usually is first connected to a control system via a fieldbus or traditional 4-20 mA dc I/O. The control system then is connected to the IT system through some type of middleware such as a database server. However, for some smart field devices, particularly those involved in process monitoring as opposed to process control, direct connection between the field device and an IT technology platform may be a better solution. “After all, the smart field device already has available, fully defined engineering values so further scaling is redundant,” adds McIntyre. This approach avoids the deterministic delivery, data management, safety and security issues associated with more-demanding control system environments. Connecting directly from the field device to the IT system also cuts costs substantially—for three reasons. First, a direct connection eliminates the need for traditional hardware components and software systems. Second, the

field device in question may not need to be part of the control system’s overall validation and maintenance program. Third, field device access can be controlled through existing IT security systems, according to McIntyre. “Many environmental applications such as EPA reporting and enterprise applications such as inventory management don’t require the millisecond update speeds or deterministic behavior inherent to most control systems; in fact, there may be prudent reasons to keep environmental reporting infrastructure separate from the control system,” says McIntyre. Some facilities have found up to 70 percent of their field measurement devices don’t have any associated real-time control functions or critical time delivery, he adds. Prying eyes After the recent Stuxnet virus attacks, most people are more aware of the need to keep their data safe and away from prying eyes. “If someone wants to get in, it doesn’t matter if it’s wired or wireless,” says McIntyre. “That’s [another] good reason to keep the controls platform separate from the monitoring system.” A good way to keep intruders out, he adds, is to have as few remote servicing points as possible. Fortunately, with wireless systems that use relatively low power, range is not that significant—compared to a licensed, high-powered system. With the limited range, an intruder

would almost have to be on site to “steal” the signal. “It would be nearly impossible to break into the system (i.e., pick up one of our packets),” says Carter, “and even if you could, what would be the value of the data? The data would be a Modbus register, so first the intruder would have to know something about Modbus, and second know the context in which it is used.” Breaking into this data stream is not the same as stealing a neighbor’s Wi-Fi, and of what importance would a tank level be to the intruder? Some suppliers are building in additional security schemes to their wireless systems. Besides using a proprietary communication protocol, T& D designed an optical registration system into its products, says Knugh. To have a product join the network, a user must have physical control of the device and register it to the data collector through a photo-array that records the new device’s serial number. Without this information in the system, the network will not “see” an unregistered device. Finding power Though many wireless sensors can be powered by AC power or DC systems, most have the ability to use internal battery power. The key to long battery life is using the least amount of power possible to minimize battery changes. This is important when wireless sensors are in hard-to-reach or

www.foodengineeringmag.com | Food Engineering | February 2011

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SENSORS

dangerous places. Depending on transmit intervals, some WirelessHART devices can work anywhere from four to 10 years on a single battery. There are, however, other sources of power, and some are more obvious than others. A simple source involves using solar cells for outdoor applications when possible; in this case, the solar cells are used primarily to recharge or hold up a sensor’s battery. Another source involves harvesting power from vibration—especially if vibration is the process variable to be measured. However, if it’s a new vibration monitoring application (meaning all new equipment), be sure there is enough vibration to power the sensor. Enough energy to power a wireless sensor can also be harvested from a temperature gradient. “We can use a small (3°C) differential in temperature to create electricity to power sensors,” says Jim O’Callaghan, EnOcean Inc. president. The heat can be harvested from machinery parts, radiators, smoke stacks or even the human body, he adds. The most important aspects of any wireless sensor that harvests energy are that users don’t have to change the battery, the sensor can be completely sealed, and it can work in any food and beverage environment. With the finalization of wireless sensor standards and research in finding ways to minimize sensor power require-

ments and harvest power from the surrounding environment, wireless sensors are filling varied roles in monitoring process applications. In addition, processors have the option to cluster several wired sensors in an application and transmit all their data to a wireless Ethernet gateway through wireless RTUs and data collectors. In terms of cost and variety of possible solutions, it would seem the sky’s the limit. ❖ For more information: Craig McIntyre, Endress+Hauser, 317-535-1368, [email protected] Kaitlin Carter, Banner Engineering, 763-512-3414, [email protected] Gareth Johnston, ABB, +44-1480-475312, [email protected] Ben Orchard, Opto 22, 951-695-3028, [email protected] Steve Knugh, T & D Corp., 518-669-9227, [email protected] Dan Dudici, Invensys Operations Management, 847-404-1288, [email protected] Russ Graybill, Yokogawa, 770-254-0400 (ext. 4467), [email protected] Ashish Desai, Omega Engineering, 203-359-1660, ext. 2326, [email protected] Jim O’Callaghan, EnOcean, 925-275-6601 Mikael Inglund, Emerson Process (Rosemount), 800-722-2865

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T E C H U P D AT E : C O O K I N G & F RY I N G Kevin T. Higgins, Senior Editor

` Growing popularity of sousvide meats is a boon for Wolf-tec’s water-emersion cookers and chillers. Molded meats and deli logs measuring 10 ft. or longer are automatically conveyed in and out of the systems, allowing processors to attain throughputs of 330,000 lbs. a day. Source: Armor Inox.

Need-driven advancements

`

Improved energy efficiency, fun shapes, healthier eating: Myriad market demands are driving changes in commercial cooking and frying systems.

I

n the 20th century, thermal workhorses such as cooking and frying systems were judged on gross throughput. In the 21st century, other factors come into play. Overall equipment efficiency forces food manufacturers to consider changeover time and product waste and rework. Rising energy costs bring operating efficiency into the equation. But perhaps the greatest influence is the change in people’s consumption patterns: W hether driven by whim or the trend toward healthier foods, those demands require manufacturers to consider versatility, flexibility and modified outcomes when evaluating equipment options. Integration of vacuum to both cooking and frying systems is a case in point.

Scientific evidence is mounting that vacuum frying results in less oil pickup in potato chips and novel vegetable and fruit chips than conventional frying. In the January edition of the Journal of Food Science, researchers reported vacuum-fried carrot and potato chips absorb half as much oil, compared to those produced via atmospheric frying. A less dramatic 25 percent reduction in oil pickup was observed with apple chips. Earlier studies have noted that vacuum frying allows a reduction in oil temperatures. Fry shortening prices are up more than 50 percent in the last year, and additional price shocks are anticipated. Technology that addresses human health concerns while lowering processing costs falls under the heading of win-win.


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T E C H U P DAT E

` Processors can apply grill marks to one or both sides of formed and natural products with Heat and Control’s Rotary Brander. Source: Heat and Control.

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To date, vacuum frying has been a curiosity in the North American market, and the few applications involving commercial products have fallen flat. Deep fryers and conventional fryers are entrenched, and healthy snacking products have come and gone. But obesity concerns put the status quo in doubt, and January’s release of the new Dietary Guidelines for Americans from USDA and the Health and Human Services department will nudge change along. Snack food manufacturers have modified product formulations in recent years to deliver healthier products with reduced sodium, sugar and fat. New equipment also is coming into play. An example is a heated de-oiling centrifuge that Hayward, CA-based Heat and Control Inc. developed for use with batch fryers. The centrifuge removes one-quarter to a third of the surface oil residing on chips as they exit the fryer, reports Doug Kozenski, sales manager-processing systems. Less oil pickup isn’t the only health benefit with vacuum frying, however. Lower operating temperatures eliminate the formation of acrylamide, the possibly carcinogenic chemical compound that forms when sugars and the amino acid asparagine found in starchy foods are subjected to high-temperature cooking. “We fry at 120°-125°C (248°-257°F) instead of 180°C (356°F), so there is no caramelization of the sugars,” explains Marcel Kloesmeijer, commercial director of BMA Nederland BV in Woerden, the Netherlands. His firm’s Florigo unit


began supplying vacuum fryers in the 1960s, when poor potato crops forced European snack manufacturers to try alternative technologies to prevent discolored chips. Vacuum frying languished as a niche technology until health concerns renewed interest in it. Several US food companies now use vacuum fryers for their European snack products. Tokyo-based Calbee Foods Co. uses more than a dozen units to produce Jagabee potato sticks, a healthy snack that has attracted a huge following since its introduction in 2006. Major US fryer suppliers have not developed vacuum systems. Reduced oil pickup comes at the expense of greater water loss, points out Ramesh Gunawardena, manager-technology & process development at JBT FoodTech, Sandusky, OH. “If you sell by weight, yield comes into play,” he cautions. “It all depends on how companies value the product.” JBT’s research and development focuses on continuous fryers. Because frying occurs in a vacuum tube, vacuum frying essentially is a batch process, a fact that limits throughput. Even the largest units, which measure 40 ft. long and 10 ft. in width, can only produce about 660 lbs. of product an hour, says Kloesmeijer. And the units are expensive. But last year, PepsiCo secured a patent for a process that incorporates a pre-fryer that can push production to 3,000 lbs. an hour. PepsiCo’s patent covers the temperature profile in a multi-stage process. BMA holds the patent on the fryer itself, and the two companies are now “linked at the hip” and will soon join forces in a promotional effort, Kloesmeijer says. Advances in IR Vacuum cooking has followed an easier technologyadoption curve, and Santa Rosa, CA-based Blentech Corp. has augmented it with kettles that also offer vacuum chilling. The technology can’t compete with scraped surface heat exchangers when consistent commodity cooling with large volumes is the goal, allows Daniel Voit, vice president & chief operating officer, but “when batch processing high-end soups, sauces and slurries, vacuum chilling becomes more attractive.” Blentech’s cook/chill vacuum technology was widely adopted in the UK market when refrigerated ready meals became a supermarket sensation. “Quality was number one on the minds of a lot of

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T E C H U P DAT E tion component with infrared. “The hotter you fire it, the longer it lasts,” Khanania boasts. “There’s nothing like it in the world.” His engineering team is adopting the burners for fryer applications. Conventional ovens rely on the convection effect of outside air to dry product, but that cooler air must be heated. “The stack has this enormous draft, and you create suction and a cooling effect,” he explains. Khanania’s burner already has a convection component, negating the need to draw in cooler air. “The only thing we want to exhaust is the energy through the burners,” he says. Khanania estimates his firm has retrofitted almost 200 ovens for PepsiCo, but the Shearer’s project gave him a clean slate to apply his burners and resulted in significantly greater efficiency.

` Some searing occurs when meat and poultry pass through a grillmark unit, but the main affect is aesthetic. Catering to diners’ desire for food that looks as good as it tastes is driving widespread installations of such equipment.

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our UK customers, and they gravitated to this,” says Voit. Problems with violent boiling while chilling with vacuum were addressed with improved controls technology, but vacuum cooling is a relatively slow process. Blentech addressed this by using the kettle’s double-walled jacket to both heat and cool. Assuming 40°F water is used, the jacket accelerates product cooling down to 104°, at which point the vacuum system kicks in. Engineering innovations in oven design that significantly reduce energy consumption are being brought to market by Souhel Khanania, president of Coppell, TX-based IET Combustion LLC. Khanania designed an oven for Shearer’s Foods’ Massillon, OH plant that lowered energy inputs 40 percent, compared to conventional ovens. A wellinsulated frame that restricts air inflow by about two-thirds accounts for part of the savings, but Khanania’s infrared burners added a higher level of technical innovation. Metal matrix emitters replaced ceramic emitter faces in food applications of infrared burners because of the risk of glass contamination and higher maintenance requirements. IR burners with a metal matrix face address those issues, but Khanania says the surface of the burners have operating temperatures approaching 2,000°F. “Metal oxidizes in a matter of months, and the higher the temperature, the faster the deterioration,” he says. His solution combines a convec-


Technology transfer Silo syndrome can prevent processors in one segment of food production from reaping the benefits of technical advances in another. That is especially true for fryers: Bakery units have not received the research and development focus that was poured into units designed for meat, poultry and snack foods. Fortunately, change is occurring. The process began a few years ago when Heat and Control built a 36 ft.-long donut fryer with a 40 in.-wide belt. The dimensions were “outside the comfort zone” of most donut fryer manufacturers, says Kozenski. Heat and Control’s expertise in zone control, temperature control and other engineering issues in meat and poultry frying helped ease the transition to baking applications. As attendees at September’s IBIE baking show in Las Vegas discovered, another meat-frying expert also is getting involved in donut fr ying. Seattle’s Belshaw Adamatic has partnered with JBT FoodTech to fabricate fryers up to 40 ft. long. More significantly, the larger units incorporate advances JBT FoodTech developed for protein frying. Commercial availability is expected this summer. The collaboration is expected to yield both quantitative and qualitative improvements. Electro-polished heat exchanger fins resist sediment sticking , resulting in less temperature differential and oil breakdown. Centrifugal filtration will effectively remove starch from the bottom of the fryer, reducing oil degradation.

` A worker performs a QA check on seasoned sweet potatoes with a temperature probe as product exits an AirForce oven. Source: Heat and Control Inc.

And while conventional donut fryers have combustion efficiencies of about 60 percent, the hybrid unit is expected to operate at greater than 80 percent efficiency. People want food that not only tastes good but also looks appealing. Some flavor enhancement, but mostly surfacecolor development, is added when infrared burners are included in a cook line to create grill marks on meat and poultry. Grill marks also can be added with “floating rings” that follow the contours of the meat as it is conveyed, says Kozenski. That’s the approach taken with Heat and Control’s “rotary brander,” a machine that heats metal rings to temperatures of 1,100°F or greater. With formed products, fixed bars create the grill marks. La joie de sous-vide Nothing says high-volume and automated production like the cook/cool/chill water emersion systems manufactured by Wolf-tec Inc., a Kingston, NY division of Armor Inox. Applied primarily to molded meats such as deli logs and hams, the system combines an age-old cooking process with advanced material handling. Two operators on two shifts

can produce 300,000 lbs. of finished goods a day, according to Josef Rohrmeier, Wolf-tec product manager. Water bath is riding the crest of sous-vide (under vacuum), the French culinary method that requires precise temperature


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T E C H U P DAT E control over extended periods as food is cooked in airtight plastic bags. Sousvide’s roots are in the 18th century, but the methodology was impractical for commercial purposes until precise temperature controls could be applied. Inexpensive PID controllers have brought sous-vide into home kitchens, but the precision of the heat application also

makes it a favorite of top chefs and foodservice operations. Just as steam cooking is much more precise than hot air, water cooking is a quantum improvement over steam. Rohrmeier says water temperatures vary less than 1°. With steam, 3°-5° variances from set point occur. Tighter tolerances also result in uniform color.

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W hen complex flavor profiles are desired, water bath isn’t an option. Surface coloration can be added by coating the inside of plastic wrappers with chemicals, though the penetration is less than 2mm, Rohrmeier says. On the plus side, a wide range of smoke flavors can be impar ted with the film. “You no longer need a smokehouse,” he says. Because water never contacts the meat, fish or other product being cooked, the water can be filtered and recirculated continuously. Wolf-tec’s largest systems employ three heat exchangers as the cook/chill cycle is repeated for each batch. All steps occur in the same tank. “It’s more economical to pump water in and out of the same tank than to transfer 15,000 lb. batches of product,” Rohrmeier points out. W hile the process has remained essentially the same for decades, new wrinkles continue to be added. The customized molds that hold Virginia hams and turkey breasts often are used to create a netting effect on molded meat without using actual nets. Molds built for Disneyland Paris are creating ham sandwiches with the profile of Mickey Mouse: a head and two ears. If energy efficiency was the only consideration, water baths would cook all meats. But energy use is only one of many criteria, just as throughput is a single consideration. Whether the objective is healthier foods, funky shapes or some other goal, cooking and fr ying technology is being modified and improved to deliver the desired results. ❖ For more information: Daniel Voit, Blentech Corp., 707-523-5949, [email protected] Marcel Kloesmeijer, BMA Nederland BV, 31-348 435 490, [email protected] Ramesh Gunawardena, JBT FoodTech, 419-626-0304, [email protected] Doug Kozenski, Heat and Control Inc.,

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

847-395-6478, [email protected] Souhel Khanania, IET Combustion LLC, 847-946-5578, [email protected] Josef Rohrmeier, Wolf-tec Inc., 845-340-9727, [email protected]


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FIELD REPORTS

ASRS minimizes energy usage, improves efficiency

`

Switching from manual cold storage warehousing to an automated storage and retrieval system improves inventory accuracy.

J

.T.M. Food Group (JTM), located in Harrison, OH, is a family-owned food processor producing meat balls, sausage links, pork chorizo, steak ranchero, beef stroganoff, chili verde and much more. All of the company’s products are cooked, packaged, frozen and distributed from its own plant. Since the late 1960s, the processor has grown exponentially into a prominent meat processor with sales exceeding $72 million in 2007. “We had been building new storage freezers every couple of years since we started the business,” says Joe Maas, JTM vice president of operations. “We

` When the Dematic ASRS machine runs up and down the aisle, it can handle four-deep pallet storage lanes on one side, and on the other side, it can handle eight-deep pallet storage lanes. Source: Dematic.

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were getting tired of the same size and type of storage freezers, so this last time, we built a really big one with 10,000 pallet locations, so that it would take care of our needs for many years. We were operating with two 700-pallet storage freezers and using outside storage, and wanted to increase our efficiency by consolidating the freezers into one space and manage all inventory internally on location at the plant.” Forklifts were another problem. “Not only do forklifts let out a tremendous amount of cold air from the freezer, they also create a lot of damage to the racking, doors and product,” says Maas. JTM selected Dematic Corp. to design and build the storage retrieval system, including control software, racking and associated conveying equipment. “The roof square footage with an ASRS is small,” Maas says. “Most of our cold loss is going to occur in the roof, so the ASRS design minimizes that,” he adds. “Our ASRS doors are six feet high and four feet wide, and when the product is passing through the door, it blocks air from getting out. Then the door shuts immediately. A standard freezer with a forklift has an eight-foot by ten-foot opening, and the door closes some time after the truck passes through, but slowly, releasing a lot of cold air.” Dematic designed the system with a double-load, remote pallet handling device that can carry two pallets at a time. When JTM’s storage retrieval machine picks up loads from manufacturing, it loads up two pallets at a time and simultaneously puts away two pallets at a time, which decreases cycle time and increases throughput. The system uses StagingDirector software for inventory management and pallet movement with the ASRS, part of the Dematic WCS (Warehouse Control System) IT Suite. This system connects with JTM’s order management system. The ASRS eliminated the excess air exchange in and out of the freezer, making it more efficient. Forklifts, along with their maintenance and labor costs, vanished. ❖ For more information: Lizbeth Tommy, 616-913-6622, [email protected].

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81

AD INDEX

Untitled-1 1 COMPANY

PHONE NUMBER

Admix Inc. Air Blast, Inc. Amerivap Systems Arizona Instrument LLC

PAGE

800-466-2369

4

626-576-0144

68

JBT FoodTech

404-350-0239

35

Key Technology

800-528-7411

Ashworth

COMPANY

K-Tron Process Group

800-782-8850

18

www.jbtfoodtech.com

71

509-529-2161

58

www.ktron.com/info-paks

15

Lubriplate Lubricants Co.

800-733-4755

57

34

Material Transfer & Storage

800-836-7068

68

888-828-4920

25

MEPACO

920-356-9900

52

Belt Technologies

800-832-2358

14

Mettler Toledo

800-221-2624

54

Bete Fog Nozzle, Inc.

413-772-0846

61

Mobil Industrial Lubricants

www.mobilindustrial.com

BC

Bimba

800-44-BIMBA

12

MPE Group

800-965-6065

10

Breddo Likwifier

800-669-4092

IBC

Nercon Engineering

920-233-3268

32

www.theaustin.com/foodgroup

Baldor Electric Company

Buhler Inc.

www.thebuhlergroup.com

22

NSF International

800-NFS-Mark

47

Bunting Magnetics Co.

800-835-2526

50

NTFE America

507-786-9494

6

Burns & McDonnell

816-822-3812

49

NuTec

815-722-2800

30-31

Charles Ross & Son Corp.

800-243-ROSS

53

Omega Engineering Inc.

800-423-4585

40

Opto 22

800-321-6786

66-67

Demaco

321-952-6600

38

Pfizer Animal Health

800-733-5500

51

Dorner

800-397-8664

56

Power Engineers

888-687-8811

55

Douglas Machines

800-331-6870

33

Reiser

781-821-1290

19

Eriez Magnetics

888-300-ERIEZ

24

Schenk Accurate

800-394-2941

36

Flexicon Coporation

888-353-9426

9

Specialty Equipment

713-467-1818

37

Flottweg Separation Technology

859-448-2300

41

Spraying Systems Co.

800-95-SPRAY

5

Fortress Technology

888-220-8737

73

SPX

www.spx.com

IFC

FPEC

479-751-9392

75

Summit Industrial Products

800-749-5823

39

Fristam Pumps

800-841-5001

7

816-891-9272

26

Gamajet

877-GAMAJET

33

909-422-1730

20

Hapman

877-314-0733

1

603-644-2500

16

Heat and Control, Inc.

800-227-5980

74

813-920-7434

21

www.dairyshow.com

27

Clayton Industries

IDFA

Wenger Wilden Pump Wire Belt Company of America Zeppelin Systems

888-82-OMEGA

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

82

10:23 AM PAGE

11

Austin Company

800-682-4594

6

JAX

8/27/10 PHONE NUMBER


2

ENGINEERING R&D Kevin T. Higgins, Senior Editor

What’s printing for dinner?

`

3D printers have followed the path of mainframe computers: unrealized potential related to unaffordable access. Thanks to a serendipitous food application, 3D is morphing into a PC. People eat with their eyes, it’s said, but the sense of sight gets short shrift with astronaut food and sci-fi conceptions of future food. Instead of delivering human nutrition in a test tube or a pill, what if it could be extruded in a form that duplicates the best nouvelle cuisine presentations? Free-form research addressing that question is part of the Fab@home project at Cornell University’s Computational Synthesis Lab (CSL). CSL was founded in 2001 by Hod Lipson, a professor of mechanical and aerospace engineering and director of graduate studies in mechanical engineering. The Fab@home project was launched four years later. Alternatively known as rapid prototyping technology, Fab@home was conceived as a way to mainstream 3D printing by creating a global community of hobbyists and others who have accessed Fab@home’s instructions and kits to built personal 3D printers. A score of Cornell researchers are involved in Fab@home, though a virtual community of thousands has been created. Industrial designers have used 3D printers to create prototype cars and prosthetic devices, typi-

` Associate Professor Hod Lipson, mechanical & aerospace engineering, and director, Computational Synthesis Lab, Cornell University, Ithaca, NY. Source: Cornell University.

cally from resins or starch, but mainstream applications—for example, fabricating a replacement part for a machine—are not practical with printers costing $40,000 or more. Making available low-cost printers that combine multiple ingredients to create cookies, turkey dinners and other foods, on the other hand, is generating mainstream excitement. Users load a recipe, or FabApp, into the machine, and the food is extruded and layered to create the desired shape and density. Grad student Jeff Lipton heads the FabApp project, under the direction of Dr. Lipson. A graduate of the Israel Institute of Technology, Lipson holds BS and PhD degrees in mechanical engineering, with a focus on CAD and artificial intelligence in design. He previously was a visiting scholar at MIT, where some work on food printing also has been done. However, the Cornell project is exploring a wider range of foods and driving down costs for the syringe-based 3D printers that create them.

FE: What was the initial focus of CSL’s 3D A high school girl in Kentucky printed the first food. printing work? She used a heated syringe to get chocolate to flow and Lipson: Though the technology has been around print line by line, layer by layer, in a three-dimensional

for 20 years, 3D printers have been very expensive. In 2005, the lab’s Fab@home project made opensource blueprints available for building a 3D printer. People could either buy the parts, easily acquired for about $1,600, or buy a kit for $2,200.

shape she had programmed. That led to our FabApps project. The reaction has been an eye-opener. There is something very fundamental about working with food. FE: What has been the biggest challenge? Lipson: Learning to deal with the rheological prop-

erties of food. It has to be soft enough to be extruded through a syringe, yet solid enough to hold its shape printed objects and circuits, but when I talk to peo- afterward. Finding the right temperature balance for ple about those applications, their eyes glaze over. the food was tricky, as was printing in high resolution. Now, when I mention food, they light up. When my mother heard about it, she wanted to know if I could FE: How has food impacted the overall project? Lipson: It’s been fascinating to see how this capprint lasagna.

FE: When did food become part of the project? Lipson: Food printing began in 2007. Originally we


83

ENGINEERING R&D ` A sugar cookie with a swirl of chocolate cookie dough cools after printing. Cornell University engineers are working with the French Culinary Institute, which has used a 3D printer to create products like a cube of turkey with celery on the inside (inset). Source: Jeff Lipton, Cornell University.

tivates people’s imagination immediately. We are on the cusp of change in the way change happens. It’s similar to the transition that occurred in computer technology. The mainframe dominated computing in the 1960s. Even then, IBM and Honeywell recognized the potential of home computing, but no one could figure out how to develop it until small companies started making PCs. Then gaming applications came along, and that created the initial market for home computing. Developments in simulation and sound technologies came about because researchers were focused on the growing community of gamers. 3D printers are following the same cycle. Would making toys, medical implants or something else popularize them? We put our printer out, not knowing how it would be used. It turns out that food is perfectly suited to this technology. Food is user friendly, everybody has some knowledge about it, and it is a very disarming application. FabApps could be to 3D printing what gaming was to home computing, creating initial interest and unleashing many people’s creative energy. FE: How central is food printing to Fab@home’s work? Lipson: Everything we’ve done with food

has been a byproduct of other work we’ve done. Our funding comes from groups like the National Science Foundation and the Defense Department, and they have no interest in printing food. But 3D printing with food is what grabs people. FE: Is there a connection between 3D printing and your work in artificial intelligence and robotics? 84

and over until you have a robot that does what you want it to do. Thousands of generations of design are involved, yet it takes the computer five minutes to do it. FE: Besides food, what are you printing? Lipson: Multi-material objects are the

Lipson: Some researchers say any

machine with intelligence and the ability to be mobile is a robot. The printer won’t be mobile, but it definitely has intelligence. Ultimately, you would want to tell the machine what food or object you want, and it would make it for you. FE: Some of your work involves machines with self-awareness and the ability to self-simulate. Might that apply to food apps? Lipson: That is a different story, but

machines with self-diagnostics and selfcorrection ability are an area of interest. Taken to the extreme, it suggests machines with the intelligence to simulate an outcome before doing anything. It would be useful for any machine to learn from the thousands of details of its work: “If these ingredients are used, the food won’t hold together, or people won’t like the way it tastes.” We’re experimenting with an evolutionary design process in which the computer breeds robots. It starts with a thousand robots of random shapes. Most are completely nonfunctional, but the computer takes the elements that do work and combines them over


focus. Food fits in perfectly with this work, and it has such complex geometry. Printing cookies was an interesting project. Cookie dough is easy to extrude, and we tried printing it with a vertical C, for Cornell. But it required multiple formulations before we could create a C that did not deform. Another interesting experiment involved turkey and celery. Neither of those is extrudable through a syringe or ink-jet nozzle, so we needed to use a binder. FE: Have you involved the university’s food science department in the FabApps project? Lipson: There have been a few e-mail

exchanges, but there hasn’t been any formal contact, and that’s my fault. Some students from the Center for Hospitality Research are working with us, as is the French Culinary Institute in New York. David Arnold, the institute’s director of culinary technology, has advised on food safety issues and the addition of hydrocolloids and other binders to print foods that don’t deform. Chefs are experimenting with the technology in their own restaurants. Some view this as a way to cut waste from current food production and distribution. As with any technology, if it isn’t explained, people aren’t sure if it’s a good thing. There are those who want to move away from technology in food, so 3D printing can be somewhat controversial. ❖

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