Food Engineering September 2011

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

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THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT

The World’s Top 100 Food & Beverage Companies

Global Power Shifts

ALSO THIS MONTH ` PERFORMANCE TOOLS FOR

CONTINUOUS IMPROVEMENT ` PACK EXPO PREVIEW ` TECH UPDATE: ROBOTICS

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September 2011 | Food Engineering | www.foodengineeringmag.com

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

Best in class 5.97%

Laggards 15.88%

2.71%

7.18%

2.1%

7.05%

1.96%

7.31%

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

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

1.04%

4.41%

See Food Master, p. 48

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September 2011 | Food Engineering | www.foodengineeringmag.com

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

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

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

Global Reach Haskell supports our multi-national customers with engineering and construction services across the globe. From our headquarters in Jacksonville, corporate offices in Atlanta, Dallas, and Mexico City, and project offices worldwide, Haskell serves our customers in Latin America, Europe, and Asia.

EPC Services Haskell has expanded its product offerings to include both process and packaging system integration. Through organic growth and acquisition, Haskell now has a full compliment of system integration engineers with years of experience in virtually every segment in the food and beverage industry. Our team of over 700 engineers and construction managers are experts in project delivery for the food and beverage industry, consumer products industry and other manufacturing industries. This diverse expertise adds value to our customers as we bring technologies and approaches from a wide range of applications to the table as we search for innovative solutions to meet their business needs.

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See Food Master, p. 67

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September 2011 | Food Engineering | www.foodengineeringmag.com

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26TH ANNUAL PACKAGING TRENDS STUDY

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

S

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

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

www.foodengineeringmag.com | Food Engineering | September 2011

87

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

72%

Product safety

54%

Increased flexibility/changeover speed

48%

Track & trace requirements

47%

Product shelf life

43%

Sustainability concerns

41%

Consumer convenience

40%

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

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

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

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

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

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September 2011 | Food Engineering | www.foodengineeringmag.com

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

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

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

57%

Install new lines

42%

Reduce capital projects

24%

Increase capital projects

27%

Create strategic alliances

19%

Purchase secondary packaging equip.

26%

Outsource to copackers

22%

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

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

September 2011 | Food Engineering | www.foodengineeringmag.com

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

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September 2011

Electromagnetic and Mechanical Vibratory Feeders |Conveyors | www.foodengineeringmag.com and Screeners • Bin Vibrators • Volumatic Feeders Food Engineering

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

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

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

All the right reasons for robots

`

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

A

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

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

www.foodengineeringmag.com | Food Engineering | September 2011

95

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

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

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

September 2011 | Food Engineering | www.foodengineeringmag.com

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

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T E C H U P DAT E

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

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

September 2011 | Food Engineering | www.foodengineeringmag.com

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Making in-flight pasta entrées bellissimo!

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

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

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

www.foodengineeringmag.com | Food Engineering | September 2011

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

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

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

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

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

A&B Process Systems Corp.

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

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

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

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

See us at PACK EXPO Las Vegas booth #S6905

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

www.foodengineeringmag.com | Food Engineering | September 2011

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

Atlas Copco Compressors LLC

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

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

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

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

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

See us at PACK EXPO Las Vegas booth #6021

See us at PACK EXPO Las Vegas booth #6602

September 2011 | Food Engineering | www.foodengineeringmag.com

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

Baldor

Beckhoff Automation

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

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

Beckhoff Automation Introduces New Food-Grade Servomotors Dynamic AM3000 servo motors in new wash-down variant In order to provide advanced motion solutions for the most demanding environments, Beckhoff Automation has released new food-grade AM3000 Synchronous Servomotors. These new FDA-compliant servomotors are designed with a resistant white surface coating making them ideal for food and beverage manufacturing, packaging and any application that requires wash-down. A further advantage, the coating adds only about 30 percent to the price of the standard versions of the servomotors, depending on the size. The coating is well-suited for use around food products and is resistant to aggressive cleaning agents. Apart from the surface coating and stainless steel shaft, the motors do not differ from the standard offerings in Beckhoff’s high performance AM3000 series. The advantage for the user is that additional motor types do not have to be ‘designed into’ the machine in the case of mixed use of coated and standard motors. Hygiene regulations in the food industry place high demands on drive and control components with regard to surfaces and materials, which must be able to withstand regular exposure and resistance to aggressive cleaners. By coating a standard servomotor to make it suitable for use around food products, Beckhoff breaks new ground: the protective white coating, which is typical in the food industry, is compliant with FDA regulations and guarantees that the products manufactured with it are not in any way tainted by chemicals when proper wash-down procedures are followed. Additionally, the IP 67 design permits use in other harsh industrial environments. Flange sizes 2…7 from the Beckhoff AM3000 series are available with this new optional surface coating. Contact: Beckhoff Automation LLC Phone: 952-890-0000 Fax: 952-890-2888 e-mail: [email protected] www.beckhoffautomation.com See us at PACK EXPO Las Vegas booth #5228

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

Bel-Ray Company

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

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

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

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

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

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

Bunting Magnetics Co.

Burns & McDonnell

Bunting Magnetics has strengthened its’ world class lineup of metal detection equipment with the addition of the Meatline 05 0 Metal Detector. The Meatline is designed for integration in vacuum fillers to examine liquid and pasty type of food products. It detects and separates any type of metal, encapsulated or free.

A Total Project Solution™: We See It Clearly Burns & McDonnell delivers Total Project Solutions™ for the food and consumer products industries. From preliminary engineering through procurement, construction and commissioning, Burns & McDonnell assists clients with fast-tomarket, innovative solutions. Our expertise includes design-build installation, process and packaging design, facility audits, alternative energy sources, food safety and food defense, new product rollouts, wastewater, HVAC design, ammonia refrigeration, HACCP reviews, and comprehensive environmental services. Moreover, our LEED®-accredited professionals provide green solutions to meet your sustainability goals.

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

Contact: Rod Henricks Product Manager - Bunting Magnetics Co. 500 South Spencer Road Newton, KS 67114 316-284-2020 [email protected] www.buntingmagnetics.com See us at PACK EXPO Las Vegas booth #5327

Commitment to Partnership Our mission is to “Make Our Clients Successful!” A full range of integrated services allows Burns & McDonnell to be flexible when projects change and successfully meet our clients’ needs. Our success in making our clients successful was affirmed by The Professional Services Management Journal. The Journal recently completed an independent survey of ArchitecturalEngineering-Construction (AEC) clients to determine their level of satisfaction with their AEC services firms. Burns & McDonnell was named one of only six firms nationally to receive the Premier Award for Client Satisfaction. Predictable Outcomes Founded in 1898, Burns & McDonnell Engineering Company, Inc. is an internationally recognized engineering, architecture, construction, environmental and consulting solutions firm. The company maintains branch offices throughout the United States and services clients around the globe. Since 1986, Burns & McDonnell has been a 100% employee-owned firm with each employee-owner taking an active interest and involvement in the performance of the firm. The food & consumer products team at Burns & McDonnell is comprised of personnel with diverse backgrounds that equip them to meet the diverse needs of our clients. Team members have practical experience with respected companies in the industry and understand the type of engineering necessary to execute projects in an efficient and cost-effective manner to produce predictable project outcomes.

Contact: Caroline Cooper Burns & McDonnell 9400 Ward Parkway Kansas City, MO 64114 816-822-3831 [email protected] www.burnsmcd.com/fcp See us at IDFA booth #518

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

Chemetall

Convenience Foods

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

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

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

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

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

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

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

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

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

See us at PACK EXPO Las Vegas booth #108

See us at PACK EXPO Las Vegas booth #3308

www.foodengineeringmag.com | Food Engineering | September 2011

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

Dur-A-Flex, Inc.

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

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

Every couple of years, you plan for shutting down production and paying to repair your floors. Worn, eroded epoxy floors become trip hazards and start to fail section by section. Hard to clean grout lines allow for places for foodstuffs and bacteria to form, providing the conditions that lead to floor repairs and replacement. Dur-A-Flex will help you stop replacing floors so soon and eliminate the loss of production and revenue caused by downtime, constant repairs and total floor replacements. Our urethane system is the new industry standard for food processing flooring. This ultra durable, seamless, resinous flooring outperforms epoxy and tile because it was specifically formulated to handle the harsh, food processing environment. It easily resists the erosion caused by food acids, grease and moisture that team up and contribute to the growth of damaging bacteria.

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

Dur-A-Flex flooring can help you knock out: • Revenue loss – quick installs to reduce downtime • Floor failure – seamless means no grout to maintain or places for bacteria to hide • Excessive wear and tear - caused by forklift/pallet jack traffic • Liability risks – reduce slip or trip hazards

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

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

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

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

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

September 2011 | Food Engineering | www.foodengineeringmag.com

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

Eriez

Mobil Industrial Lubricants

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

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

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

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

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

See us at PACK EXPO Las Vegas booth #7030

www.foodengineeringmag.com | Food Engineering | September 2011

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Fortress Technology Inc.

Fristam Pump

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

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

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

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

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

Contact: Fristam Pumps USA 800-841-5001 www.fristam.com/usa See us at PACK EXPO Las Vegas booth #6402

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

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

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

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

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

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

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

JBT FoodTech

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

For the latest freezing and cooking technologies, JBT FoodTech continues to lead the way. The famous GYRoCOMPACT® spiral freezer, which includes the popular M series of freezers, is now available with several new upgrades for hygiene and sanitation: stainless steel fully seam welded enclosure, hygienic evaporator coil features and, lighter and stronger FRIGoBELT® M for higher freezing capacity . For high capacity, boxed product applications, Odenberg Variable Retention Time (VRT) freezers and chillers are now sold by JBT FoodTech in North America. From yogurt cooling to freezing boxed meat, the Odenberg VRT can integrate with existing cold storage warehouses to process large capacities of up to 50,000 lb/hr. The Double D Searing Oven with optional Bar Marker adds unique color and texture to products. For processors looking for the most economical way to extend oil life, the MicroMax™ (MX) Centrifugal Oil Filter is a proven winner. The new MX-II operates as a centrifuge to continuously filter out oil sediment down to 5-micron particles.

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

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

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Contact: Key Technology, Inc. 150 Avery Street Walla Walla, WA 99362 USA Tel: 509 529 2161 Fax: 509 527 1331 Email: [email protected] URL: www.key.net See us at PACK EXPO Las Vegas booth #4509

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

Lubriplate Lubricants Company

Magnum Systems

Lubriplate Lubricants Company is a producer of high performance, long life, synthetic lubricants. These lubricants provide superior lubrication and protection for all types of industrial machinery, food processing and bottling machinery as well as construction, automotive and marine equipment. The company has executive offices in Newark, New Jersey and manufacturing facilities in Toledo, Ohio. Lubriplate Lubricants are backed by an international system of local distributors. The company is ISO 9001 Registered.

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

Of special interest is the major market position Lubriplate enjoys in the field of food processing and bottling machinery lubrication. These Lubriplate NSF H-1 Registered lubricants meet FDA regulations 21 CFR 178.3570 and 21 CFR 172.882. They are certified OU Kosher Pareve and HALAL registered. The manufacturing process for these H-1 lubricants is ISO 21469 Compliant. The use of Lubriplate H-1 lubricants throughout your plant operations can significantly simplify your HACCP program by eliminating lubrication as a potential chemical hazard. Sales, marketing and technical staff can be reached at 1-800-733-4755 or e-mail [email protected]. Their webpage is www.lubriplate.com. Specific lubrication questions can be addressed to [email protected].

Contact: Mr. Jim Girard, VP & CMO Lubriplate Lubricants Company 129 Lockwood Street NEWARK, NJ 07105 1-800-733-4755 www.lubriplate.com See us at PACK EXPO Las Vegas booth #S-6118

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

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

METTLER TOLEDO

Reiser

METTLER TOLEDO invites you to a total 360° Product Inspection experience with a chance to see how our solutions can look at your inspection challenges from every angle. Visit us in Booth C541 and learn how our solutions can increase efficiency, reduce manufacturing costs and improve the competitiveness of your business and you could win $1,000 gift certificate for Travelocity! METTLER TOLEDO provides in-line product inspection solutions for the packaging industry with CI-Vision machine vision inspection systems, Hi-Speed checkweighers, Safeline metal detectors and Safeline x-ray inspection systems. Our broad product inspection line ranges from very basic and economical systems to sophisticated, state-of-the-art systems with customized material handling solutions. Depending on your specific requirements, our systems can ensure perfect product presentation, verify package and label integrity, ensure weight range compliance, detect physical contaminants and inspect contents inside the closed package. Machine Vision METTLER TOLEDO CI-Vision inspection systems ensure that products consistently meet manufacturers’ quality standards and specifications resulting in perfect product presentation every time. Checkweighing METTLER TOLEDO Hi-Speed dynamic checkweighing systems ensure 100% quality control, minimize costly giveaway and give you total peace of mind. Metal Detection METTLER TOLEDO Safeline metal detection systems prevent costly recalls by ensuring your products are free of ferrous, non-ferrous and stainless steel contaminants which can be introduced during processing.

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

X-ray Inspection METTLER TOLEDO Safeline x-ray inspection systems can detect ferrous, non-ferrous, stainless steel, glass and stone contaminants, detect mass and check for missing or damaged product inside closed packages.

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

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

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

See us at PACK EXPO Las Vegas booth #C-541

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

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

SIEMENS

SlipNOT® Metal Safety Flooring

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

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

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

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

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

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

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

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

Spraying Systems Co.

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

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

Contact: Tim Oberg [email protected] Spraying Systems Co. North Avenue and Schmale Road, PO Box 7900 Wheaton, IL 60187-7901 USA 800-95-SPRAY www.spray.com

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

See us at IDFA booth #813

See us at IDFA booth #1213

September 2011 | Food Engineering | www.foodengineeringmag.com

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

Vac-U-Max

Woodard & Curran

VAC-U-MAX specializes in design and manufacture of pneumatic systems and support equipment for conveying, weighing and batching of dry materials. The primary technology for conveying is vacuum, but positive pressure pneumatic systems as well as mechanical conveyors are used as applications dictate. An equally important activity is design and manufacture of heavy duty industrial vacuum cleaners, ranging from small air and electric powered drum styled units to large electric and diesel powered units.

Markets Served VAC-U-MAX equipment and systems are sold worldwide. Major markets for conveying systems include the chemical, food and pharmaceutical industries. Specialty applications include conveying of small parts and objects, including coins and heavy metal powders.

Technologies A pioneer in vacuum pneumatic conveying, VAC-U-MAX has had many firsts, including air-powered venturi power units, direct-loading of vacuum-tolerant process equipment and vertical-wall “Tube Hopper” material receivers. A UL-listed designer and manufacturer of control panels, VAC-U-MAX furnishes integrated control systems that provide coordination of material movement, batching, and processing, with tie in capabilities to existing control systems.

Major Products Pneumatic Conveying Systems • Dilute Phase Vacuum Conveying Systems • Dense Phase Vacuum Conveying Systems • Dilute Phase Positive Pressure Conveying Systems • Dense Phase Positive Pressure Systems • Multi-ingredient Handling • Batch Weighing Systems • Bulk Bag Unloading • Bulk Bag Loading • Bag Dump Stations • Gravity Diverter Valves • Aero-Mechanical Conveyors • Flexible Screw Conveyors

Pneumatic Conveying Systems

Industrial Vacuum Cleaning Equipment • Air Operated Drum Top Vacuum Cleaners • Electric Drum Top Vacuum Cleaners • Continuous Duty Portable Electric Vacuum Cleaners • Central Vacuum Cleaning Systems • Hose, Tools, and Accessories • Tubing, Couplings, and Fittings

Aero-Mechanical Conveyors

Flexible Screw Conveyors

www.vac-u-max.com

See us at PACK EXPO Las Vegas booth #5121

Woodard & Curran delivers sustainable designs and optimum performance to Food and Beverage industry clients. We have designed, permitted, and installed some of the most efficient manufacturing facilities in the world for beverage, dairy, protein, snack food, dressings and dips, and sauce manufacturers. The bundle of services Woodard & Curran offers is extensive. We provide the complete design, installation, startup, and environmental health and safety support needed for process lines and associated utility infrastructure, including: • Packaging equipment specification; • Bottle manufacturing design; • Manufacturing line layout design; • Water and wastewater; • Sustainability and product environmental footprinting; • Energy management; • Environmental compliance; • Compressed air; • Refrigeration and chilled water; and • Water resource management and hydrogeology. As an integrated science and engineering company, our clients have access to expertise a wide array of disciplines such as information management, automation (instrumentation and controls), training, site-civil permitting and design, and contract operations. We build successful partnerships and apply proven approaches to lean manufacturing. We deliver value by integrating best-in-class components that lower maintenance costs, decrease downtime, and increase efficiency. We measure success in line efficiency, waste minimization, streamlined handling, and plant flexibility with regard to both products and line balance. Woodard & Curran is a 600-person, integrated engineering, science, and operations company. Privately held and steadily growing, we serve public and private clients locally and nationwide. Contact: Woodard & Curran Eric Carlson, PE Senior Vice President 41 Hutchins Drive, Portland, ME 04102 800.426.4262 [email protected] www.woodardcurran.com See us at PACK EXPO Las Vegas booth #6328

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Call CXR COMPANY • Warsaw, IN 800-817-5763 • fax 574-269-7140 www.cxrcompany.com

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EQUIPMENT FOR SALE

ENGINEERING .COM EERING

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www.foodengineeringmag.com | Food Engineering | September 2011

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EQUIPMENT FOR SALE

N FREEZE WITH EASE O A practical, inexpensive and immediate solution to your cold storage needs. visit us on our web site: www.kellyfreezer.com We Sell Worldwide W Used Carriers in 20 foot and 40 foot sizes R starting at $9,500 E N New BOHN Coolers and Freezers T starting at $10,500 Blast Freezers starting I at $34,500 N G Thinking about Cold Storage?

Phone: 1-866-713-6307 Fax: 1-860-668-2871

Privately owned and operated for over 40 years. Kelly can handle your freezer/ cooler needs from -30 F to 45 F. Ground level, dock height, lighting, walk in doors, insulated roll up doors and most custom features available.

Great Lakes Separators Now Available: Reconditioned ALFA-LAVAL and WESTFALIA Separators Consultants: Dick Lambert, Rick Veneer and Bill Gooderham

Call Dave Lambert (920)863-3306 130

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September 2011 | Food Engineering | www.foodengineeringmag.com

EQUIPMENT FOR SALE

FOR SALE/RENT 24 / 7 EMERGENCY SERVICE BOILERS › 20,000-400,000 #/Hr. DIESEL & TURBINE GENERATORS › 50-25,000 KW GEARS & TURBINES › 25-4000 HP WE STOCK LARGE INVENTORIES OF: !IR0RE (EATERSs%CONOMIZERSs$EAERATORSs0UMPSs-OTORSs&UEL/IL(EATING0UMP3ETS 6ALVESs4UBESs#ONTROLSs#OMPRESSORSs0ULVERIZERSs2ENTAL"OILERS'ENERATORS

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AUCTION ALERT DBC FOODS St. Cloud, Minnesota October 5th, 2011 10:00 a.m. CST Onsite & Online This is a Complete Sausage, Smoked Meats, Ham, Soup, Salads and Further Processing Plant. Including All Plant Refrigeration & Support Equipment. All Late Model Equipment. Sale conducted in conjunction with Go Industry-Dove Bid. To Bid Online Register At www.Bidspotter.com, For Complete Information Go To www.Barliantauctions.com, Email [email protected] 16 10 018 or Call (630)553-6992. Scott Swanson, MN License # 16-10-018

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PACKAGING

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AD INDEX

April 22-25, 2012 Sanibel Harbour Marriott COMPANY

PHONE NUMBER

PAGE

•

COMPANY

Fort Myers, FL PHONE NUMBER

A&B Process Systems

888-254-2789

74

Industrial Magnetics, Inc.

888-582-0821

47

Admix Inc.

800-466-2369

52

JAX

800-782-8850

20

626-576-0144

42

JBT FoodTech

www.jbtfoodtech.com

5

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

106 40

Lubriplate Lubricants Co.

800-733-4755

11

800-833-0081

50

Marchant Schmidt Inc.

920-921-4760

14-17

800-528-7411

Austin Company

BD Biosciences

6

Key Technology

509-529-2161

800-652-2532

42

Masosine Process Pumps

800-282-8823

51

www.theaustin.com/foodgroup

39

Material Transfer & Storage

800-836-7068

26

888-828-4920

81

Mettler-Toledo Safeline

www.bdbiosciences.com

27

Mobil Industrial Lubricants

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

Bel-Ray

www.-bel-ray.com

2

Bimba

800-44-BIMBA

12

Breddo Likwifier

800-669-4092

IBC

Martin Brothers

94

83

Baldor Electric Company

Beckoff

888-893-9277 404-350-0239

800-682-4594

Ashworth

Mueller

800-221-2624

33

www.mobilindustrial.com

BC

800-MUELLER

22

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

800-628-8139

46

Perfex

Buhler Aeroglide

919-851-2000

49

Process Expo

101

www.nord.com

Omega Engineering Inc.

Brookfield Engineering

70-71

888-82-OMEGA

1

800-848-8483

24

www.myprocessexpo.com 60-61

Bunting Magnetics Co.

800-835-2526

104

Power Engineers

888-687-8811

Burns & McDonnell

816-822-3831

65

Reid Supply Company

800-253-0421

43

Chemetall

800-526-4473

55

Reiser

781-821-1290

86

Clarion White Oils

34-35

Relco

320-231-2210

6

320-252-8200

82

Rytec

888-GO-RYTEC

51

Demaco

321-952-6600

32

Ross, Charles & Son Company

800-243-ROSS

21, 23

Dorner

800-397-8664

37

Schenk Accurate

800-394-2941

56

Douglas Machine

800-331-6870

59

Siemens

800-253-3539

54

SlipNOT Metal Safety Flooring

97

Sonic Air Systems

Emerson Micro Motion

855-MY-CLARION

105

DCI Inc.

Dur-A-Flex

800-992-1776

Eriez Magnetics

888-300-ERIEZ

18, 92

Flexicon Coporation

888-353-9426

30

SPX

www.usa.siemens.com/foodbev 103

Spraying Systems Co.

800-SLIPNOT

38

800-82-SONIC 800-95-SPRAY

36 80, 93

www.spx.com

IFC

Flottweg Separation Technology

859-448-2300

46

Summit Industrial Products

800-749-5823

44

Fortress Technology

888-220-8737

102

Tel-Tru Manufacturing Co.

800-232-5335

59

Terlet USA

800-965-6065

10

Thermo Scientific

800-227-8891

73

Triple S Dynamics, Inc.

877-542-8010

9

77

Ultrachem Inc.

302-325-9880

47

219-464-4811

91

800-822-8629

69

Fristam Pumps

800-841-5001

7

Gamajet

877-GAMAJET

52

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

800-722-6622

45

Urschel Laboratories, Inc.

Hapman

877-314-0733

99

Vac-U-Max

Harpak

800-813-6644

58

Wenger

816-891-9272

28

Haskell

904-791-4500

84

Wire Belt Company of America

603-644-2500

89

800-227-5980

41

Woodward & Curran

www.woodwardcurran.com/fe

79

877-292-5715

48

Zeppelin Systems

813-920-7434

50

Heat & Control Hinds-Bock Corporation Inpro/Seal

www.inpro-seal.com

4

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

134

PAGE

September 2011 | Food Engineering | www.foodengineeringmag.com

ENGINEERING R&D Kevin T. Higgins, Senior Editor

New solution for slaughter

`

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

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

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

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

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

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

www.foodengineeringmag.com | Food Engineering | September 2011

135

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

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

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

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

Cheek: We had never built a convey-

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

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

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

September 2011 | Food Engineering | www.foodengineeringmag.com

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

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

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

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

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