SPECIAL REPORT: PROCESSORS BALANCE THE NEED FOR AUTOMATION VS. FLEXIBILITY October 2011
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THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT
State of Food Manufacturing
Processors Trim Spending
ALSO THIS MONTH `
LEGACY SYSTEMS: WEIGHING THE COSTS, BENEFITS, RISKS ` PROCESS EXPO PREVIEW ` TECH UPDATE: PUMPS
! NEW Slicer® n a r ET
Urschel Cutting Solutions Built‐in Performance and Durability Urschel Laboratories, Inc. manufactures over 40 different models of quality size reduction machinery to meet processors’ diverse needs. Built in performance and durability is manufactured into every model by using the strictest checks through out the production process and the best materials. UNIFORMITY Each Urschel machine uniformly delivers maximum product within the customers’ targeted specifications. FLEXIBILITY Interchangeable cutting components enable a full range of slices, dices, granula tions, or particle sizes. MAXIMUM PRODUCTIVITY Urschel cutting equipment is easily integrated into any production line and offers continuous operation to promote high throughputs. Simplified design provides ease of routine maintenance and changeover of parts. URSCHEL LABORATORIES, INC. Email:
[email protected] Phone: (219) 464‐4811 PO Box 2200, 2503 Calumet Avenue Valparaiso, IN 46384‐2200 U.S.A. ®Urschel is a registered trademark of Urschel Laboratories, Inc.
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O CTO B E R 2011
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FEATURES
Brick & mortar projects still struggling
COVER STORY
66
The State of Food Manufacturing Staff expansions and production efficiencies are bright spots in an industry feeling the effects of economic forces beyond its control.
Legacy Systems: Weighing the Costs, Benefits and Risks Most replacement systems will, or at least should, provide marginal benefits over your legacy system.
89
Flexible Manufacturing: The Automation Conundrum
Tech Update: Pumps The right pump used for the right application can make a significant difference in energy consumption.
600 500 400 300
Flexibility is an increasingly important attribute, but manufacturing professionals must strike a balance between the need for high-speed automation and production adaptability.
99
Total Projects* Expansions/Renovations New Plants
700 Number of projects
79
800
200 100 2001
2002
2003
2004
2005
2006
2007
2008
2009
2010 14-year average
*Based on projects valued at $1 million or more Source: Food Engineering’s Food Plant Construction Survey.
DEPARTMENTS 8
70
Editor’s Note
10
Calendar of Events
13
Manufacturing News PROCESS EXPO heads to Chicago bigger than 2010 show.
19
Food Packaging Front-of-package slugfest
25
89
Ode to the pallet
27
112
Join FE’s Group on LinkedIn Food Engineering Magazine
Field Reports Snack food maker cleans up its wastewater.
Follow FE on Twitter http://twitter.com/FoodEng
Technology Sourcebook Focus on Kettles, Tanks, Process Vessels and Marking & Coding Equipment
Connect with FE on Facebook www.facebook.com/FoodEngineering
Food Safety
115
PROCESS EXPO Preview
135
Classified Advertising
143
Engineering R&D GE salmon swim upstream.
www.foodengineeringmag.com | Food Engineering | October 2011
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EDITORIAL Joyce Fassl Editor in Chief
[email protected], 610-436-4220 ext. 8519 Kevin T. Higgins Senior Editor
[email protected], 847-405-4045 Wayne Labs Senior Technical Editor
[email protected], 215-345-4548 Morgan Smith New Products Editor
[email protected] Richard Stier, Jaan Koel, Allen Merritt, Mark Huffman, Olin Thompson Contributing Editors ART & PRODUCTION Karla Fierimonte Art Director
[email protected] Suzanne Fairman Advertising Production Manager
[email protected], 253-946-6854 MARKETING Marge Whalen Food Automation & Manufacturing Conference Manager
[email protected], 847-405-4071 Amy Kozyra Marketing and Event Coordinator
[email protected], 847-405-4022 Chris Frost ProcessTechnologyXchange
[email protected], 952-224-4390 Jill L. DeVries Corporate Reprint Manager
[email protected], 248-244-1726 LIST RENTAL Kevin Collopy Postal Contact 800-223-2194 x684,
[email protected] Michael Costantino Email Contact 800-223-2194 x748,
[email protected] AUDIENCE DEVELOPMENT Amy Schuler Group Audience Development Manager Megan Neel Corporate Fulfillment Manager Carolyn M. Alexander Audience Audit Coordinator
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[email protected] FOOD ENGINEERING Volume 83, Issue 10 (ISSN 0193-323X) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
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