Food manufacturing september 2015 by Aso de Ingeniería Química

www.foodmanufacturing.com ■ September 2015

Also Inside and Trace • Track Technology Yields Benefits for Food Manufacturers p. 18 Maintenance: • Equipment Food Manufacturing's Secret Ingredient p. 28

Technology for Today’s Food Production & Packaging Market Vol. 28, No. 5

EXPO Las Vegas: • PACK FSMA Compliance for Food Manufacturers, Equipment Suppliers p. 30

A Leader In Its Field With more than 60 family growers in its co-op, Oregon Cherry Growers is the largest processor of sweet cherries in North America. Cover Story p. 20

■

September 2015

FOOD SAFETY

IS JOB ONE KEEPING YOUR MACHINERY UP AND RUNNING IS A CLOSE SECOND Lubriplate NSF H1 Registered Lubricants do more than keep your machinery running at its best. They free you from the potential chemical hazard risks posed by Non-Food Grade Lubricants. In fact, using 100% Lubriplate H1 Lubricants throughout your plant can signifcantly simplify your HACCP program by completely eliminating lubricants as a potential chemical hazard.

High Performance NSF H1 Registered

Synthetic and Pure USP White Mineral Oil-Based Lubricants. Food Machinery Grade for Safe, Non-Toxic Lubrication.

FDA COMPLIANCE - With Regulations 21 CFR 178.3570, 21 CFR 178-3620, 21 CFR 172-878, 21 CFR 172.882 & 21 CFR 182

Backed By:

Lubriplate 速

ESP

Extra Services Package Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 www.lubriplate.com / LubeXpert@lubriplate.com

00_Food Manufacturing Sept2015_FINAL.indd 2

Plant Surveys / Tech Support / Training Color Coded Lube Charts & Machine Tags Lubrication Software / Follow-Up Oil Analysis

28/08/2015 20:01

contents

September 2015

www.foodmanufacturing.com

A Leader In Its Field 20 C over Story: With more than 60 family growers in its co-op, Oregon Cherry Growers is the largest processor of sweet cherries in North America.

18 Exclusive Feature: Plant Connectivity

T rack and Trace Technology Yields Multiple Benefits for Food Manufacturers

26 Questions & Answers: Thermal Processing

Camilla Howard of Unitherm Food Systems discusses the topic of thermal processing in the food manufacturing industry

28 Exclusive Feature: Equipment Maintenance

Equipment Maintenance is the Food Manufacturing Industry's Secret Ingredient

ad index

30 PACK EXPO Las Vegas 2015: FSMA Compliance for Food Manufacturers and Equipment Suppliers 38 Industry Insider: Bakery

Gluten-Free Trend Poses ‘Sticky’ Issue for Dough

9 What's the Buzz? — Insiders reflect on the latest news 12 Food Safety Update — Regulatory Compliance 34 Product Review — Latest product releases

The Advertising Index is provided as a reader service. Although every attempt has been made to make this index as complete as possible, the accuracy of all listings cannot be guaranteed.

APEC-Automated Process Equipment Corp . . . . . . . . . . . . . . 32 Arizona Polymer Flooring . . . . . . . . . 19 Bel-Ray Company. Inc. . . . . . . . . . . . 7 BinMaster. . . . . . . . . . . . . . . . . . . . . . 36 Cablevey Conveyors . . . . . . . . . . . . . 31 Citgo Petroleum Co. . . . . . . . . . . . . . 25 CRC Industries Inc. . . . . . . . . . . . . . . 15 Dorner Manufacturing Corp . . . . . . . 33 Dynamic Conveyor Corporation. . . . 10

Flexco. . . . . . . . . . . . . . . . . . . . . . . . . 39 General Electric. . . . . . . . . . . . . . . . . . 3 Goff’s Enterprises. . . . . . . . . . . . . . . . 29 Habasit America. . . . . . . . . . . . . . . . . . 9 Klabin S/A. . . . . . . . . . . . . . . . . . . . . . 13 Leem Filtration Products Inc. . . . . . 37 Lubriplate Div/ Fiske Brothers . . . . . . 2 Material Transfer & Storage. . . . . . . . 17 Meltric Corporation . . . . . . . . . . . . . . 37 Motion Industries Inc. . . . . . . . . . . . . 40

Nelson-Jameson, Inc. . . . . . . . . . . . 10 PMMI/Pack Expo. . . . . . . . . . . . . . . . 11 Ralphs-Pugh Co Inc. . . . . . . . . . . . . . 14 Sterling. . . . . . . . . . . . . . . . . . . . . . . . 18 Sturtevant, Inc. . . . . . . . . . . . . . . . . . 35 Terlet/MPE . . . . . . . . . . . . . . . . . . . . . 37 The Linde Group . . . . . . . . . . . . . . . . 21 United Rentals. . . . . . . . . . . . . . . . . . . 5 Xchanger Inc . . . . . . . . . . . . . . . . . . . 37

FOOD MANUFACTURING® (ISSN #1056-5078, USPS #006-428), (GST Reg. #844559765) is a registered trademark of and published 7 times bi-monthly except in September and October by Advantage Business Media, 100 Enterprise Drive, Suite 600, Box 912, Rockaway, NJ 07866-0912. All rights reserved under the U.S.A., International, and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, electronic recording or otherwise, without the prior written permission of the publisher. Opinions expressed in articles are those of the authors and do not necessarily reflect those of Advantage Business Media or the Editorial Board. Periodicals Mail postage paid at Rockaway, NJ 07866 and at additional mailing offices. POSTMASTER: Send return address changes to FOOD MANUFACTURING, P.O. Box 3574, Northbrook, IL 60065-3574. Publication Mail Agreement No. 41336030. Return undeliverable Canadian addresses to: Imex/Pitney Bowes, P.O. Box 1632, Windsor Ontario N9A 7C9. Subscription Inquiries/Change of Address: contact: Omeda Customer Service, P.O. Box 3574, Northbrook, IL 60065-3574, 847-559-7560, Fax: 847-291-4816, email: abfm@omeda.com. Change of address notices should include old as well as new address. If possible attach address label from recent issue. Allow 8 to 10 weeks for address change to become effective. Subscriptions are free to qualified individuals. Subscription rates per year are $54 for U.S.A., $63 for Canada, $108 for Mexico & foreign air delivery, single copy $7 for U.S.A., $14 for other locations, prepaid in U.S.A. funds drawn on a U.S.A. branch bank. Notice to Subscribers: We permit reputable companies to send announcements of their products or services to our subscribers. Requests for this privilege are examined with great care to be sure they will be of interest to our readers. If you prefer not to receive such mailings, and want your name in our files only for receiving the magazine, please write us, enclosing your current address mailing label. Please address your request to Customer Service, P.O. Box 3574, Northbrook, IL 60065-3574. Printed in USA: Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever. The editors make every reasonable effort to verify the information published, but Advantage Business Media assumes no responsibility for the validity of any manufacturers' claims or statements in items reported. Copyright ©2015 Advantage Business Media. All rights reserved.

September September 2015 2015nn

00_Food Manufacturing Sept2015_FINAL.indd 4

28/08/2015 20:01

When it comes to service and support, bigger really is better. No two jobs are the same. The same is true for equipment providers. Count on the world’s largest equipment rental provider for 24/7 response, onsite service and repair day or night, and an integrated branch network of over 880 locations. Deadlines matter. We’re here to help.

Anytime, anywhere, on any device Manage your rental feet with UR Control® UnitedRentals.com/URcontrol

UnitedRentals.com | 800.UR.RENTS

00_Food Manufacturing Sept2015_FINAL.indd 5 15-URI-0552 FoodManufacturing_May R02.indd 1

28/08/2015 20:01 4/8/15 3:05 PM

editor's note

www.foodmanufacturing.com

Telling a Sweet Success Story

Volume 28, No. 5 973-920-7000 • Fax: 973-920-7531

Jesse Osborne, Editor jesse.osborne@advantagemedia.com

General Manager, Manufacturing Group TOM LYNCH • 973-920-7782 tom.lynch@advantagemedia.com

here are many distinct areas in the food manufacturing industry. As someone who was born, raised and lives in Wisconsin, I am well-versed in my state's affinity for, and involvement with, the dairy industry. Over the course of my year-plus as editor of Food Manufacturing, I've had the opportunity to see the inner workings of companies that produce products for the meat and poultry, beverage, confection and snack food segments of the food industry. This issue of FM, however, takes a closer look at the fruit industry, specifically focusing on Oregon Cherry Growers — the largest processor of sweet cherries in North America. Associate Editor Kari Imberg has penned an interesting and informative story on OCG, which has three facilities and more than 60 family growers in its co-op. The story details that OCG, which produces 21 varieties of cherries, is also the largest cherry supplier to the ice cream industry. “You pretty much name the brand and we are the primary supplier for that,” says Kent Spalding, OCG's VP of Sales and Marketing. OCG's products can also be found in other consumer products such as dairy, bakery, cereal and baked and slab bars. Also in this issue, James Cook of SGS Food Safety Services takes a look at why food regulatory compliance seems so complicated and what can be done to simplify it. Aptean's Jack Payne tells us why track-and-trace technology yields multiple benefits for food manufacturers, and Heather Betts of Advanced Technology Services explains why equipment maintenance is the food manufacturing industry's secret ingredient. We're also taking a look at what FSMA final rules and compliance mean for food manufacturers and equipment suppliers in the second part of our PACK EXPO Las Vegas preview. And we close out the issue with a look at how the gluten-free trend poses a "sticky" issue for dough, courtesy of Linde LLC's Mark DiMaggio. As always, thank you for reading.

Editorial Director JEFF REINKE • 973-920-7784 jeff.reinke@advantagemedia.com

Associate Editor Bids Farewell to FM Dear readers, it is with a heavy heart that I say my farewells, as I am moving on to another professional opportunity. For the past year-and-a-half, I have assumed the role of associate editor for Food Manufacturing. And what a learning experience it has been! I have thoroughly enjoyed getting to learn about the ins and outs of food processing — traveling to various states to tour some top-notch food companies. I also had the pleasure to attend industry trade shows, like Pack Expo and the Food Safety Summit. I will carry these experiences with me, and cherish the time so many of you have taken to share your stories with me. Thanks so much for your loyal readership. And who knows, perhaps our paths will cross again someday. — Kari Imberg

Mixing Things Up Our website — foodmanufacturing.com — and e-newsletters feature a variety of content on a daily basis, and we are excited about the recent launch of our new video series In the Mix. In the Mix features editors from Food Manufacturing and sister brand Chem.Info offering up news, opinion and analysis on the latest happenings in the food and chemical processing realms. Take a minute to check it out and let us know what you think. u September 2015

00_Food Manufacturing Sept2015_FINAL.indd 6

Editor JESSE OSBORNE • 973-920-7020 jesse.osborne@advantagemedia.com Associate Editor KARI IMBERG • 973-920-7795 kari.imberg@advantagemedia.com Advisory Board

Andy Juarez, Engineering Manager, Tree Top Inc. Steve Van Tassel, CEO, Weetabix North America Craig Shiesley, General Manager of Silk, White Wave Foods advertising/SALES:

Regional Vice President Sales margie rogers • 973-920-7075 margierogers@advantagemedia.com Regional Director of Sales DAVID OLESTON • 973-920-7706 david.oleston@advantagemedia.com For subscription related matters please contact: ABM@omeda.com<mailto:ABM@omeda.com> Or phone them at: 847-559-7560, or fax requests to: 847-291-4816 List Rentals Infogroup Targeting Solutions Senior Account Manager, Bart Piccirillo, 402-836-6283, bart.piccirillo@infogroup.com Senior Account Manager, Michael Costantino 402-863-6266; michael.costantino@infogroup.com Reprints the ygs group reprints@theygsgroup.com 1-800-290-5460 3650 West Market Street • York, PA 17404 973-920-7000; Fax: 973-920-7531 Chief Executive Officer Jim Lonergan Chief Operating Officer/Chief Financial Officer Theresa Freeburg Chief Content Officer BETH CAMPBELL

September 2015

n 28/08/2015 20:01

PURE EFFICIENCY Premium No-Tox ® Food Grade Products Increase Efficiency & Reduce Operating Costs Reduce Wear & Extend Component Life Multiple Lubrication Capabilities

SAVE Time SAVE Money

Bel-Ray’s high-performance industrial Food Grade greases and oils are specially engineered to withstand the effects of load, heat, water and dust. Maximize performance and reduce downtime by using superior lubricants from Bel-Ray®.

SEE THE ENTIRE LINE OF BEL-RAY ® PRODUCTS AT BELRAY.COM

00_Food Manufacturing Sept2015_FINAL.indd 7

28/08/2015 20:01

ONLINE

top news

1 Dead, 2 Taken to Hospital After Ammonia Leak at Ontario Food Company Kraft Recalls 36K Cases of Cheese ConAgra to Sell Store-Brand Food Business Blue Bell: $125M Investment Necessary to Remain Operational General Mills to Slash up to 725 Jobs Blog

Social Media Matters (Even For Manufacturers)

Infographic:

By Kari Imberg, Associate Editor Perusing the Food Manufacturing Twitter page this morning, I came across one of today's trending hashtags: #SMDay. Today is being touted as Social Media Day 2015, and many companies are sharing their best tactics and resources for "boring" industries to create great content.

Blog

Can American Manufacturing Afford a Raise? By Melissa Fassbender, Editor, Pddnet.com How will Obama's plans to extend overtime protection affect economic growth?

How Consumers Opt to Reduce Excess Sugar Intake

video

Blog

The Billionaire Behind Blue Bellâ&#x20AC;&#x2122;s Comeback Bid By Meagan Parrish, Editor, Chem.info Sid Bass, who made his fortune off oil, has invested an undisclosed amount in the marred ice cream company to help get their sweet treats back on shelves.

In the Mix: Busted! The Truth Behind 3 Food Fads September 2015

00_Food Manufacturing Sept2015_FINAL.indd 8

n 28/08/2015 20:01

I do think we’d be better off as a nation if we had for poultry producers a disaster program similar to what we have for livestock producers . — Agriculture Secretary Tom Vilsack, on the bird flu outbreak that killed 48 million birds in 15 states.

We hope the judge will see that Stewart Parnell never meant to hurt anyone . He ate the peanut butter himself . He fed it to his children and to his grandchildren . — Ken Hodges, one of the attorneys of former Peanut Corporation of America owner Stewart Parnell, on federal prosecutors recommending a life sentence in prison for the peanut salmonella case that killed nine and sickened more than 700 people.

Food waste is like the band Rascal Flatts . It can fill a surprising number of stadiums even though many people consider it complete garbage . — Last Week Tonight’s Host John Oliver, on the alarming amount of food that gets thrown away each year.

I’m just a rock ‘n’ roller who believes people should know what they’re eating .” — Rocker Neil Young, on his support for the Vermont food labeling law.

Industry-leading monolithic belts Advanced fabrication and selection Habasit Cleandrive™ fat monolithic belting is now available in 48” width.

Hygienic gussets

Superior sanitation

Advanced Fabrication Capabilities: • scoops • sprockets • sidewalls • gussets • guides • cleats

Habasit America 805 Satellite Blvd. Suwanee, GA 30024

800.458.6431 habasitamerica.com info.america@us.habasit.com

00_Food Manufacturing Sept2015_FINAL.indd 9

Corded monolithic belt in 48”

Habasit Cleandrive™ boasts hydrolosis-resistant material, tight turn radius for closer transfers, and embedded cords to minimize belt “creep” or continuous elongation.

Habasit – Solutions in motion

28/08/2015 20:01

By The Numbers Percentage of consumers that make it a point of getting plenty of protein:

Amount of daily calories consumers should get their added sugars from:

200 or less (FDA)

(Packaged Facts)

The year the Little Debbie snack cakes trademark was registered:

1962 (Little Debbie)

The amount of money the U.S. government expects to pay chicken and turkey farmers for birds lost to avian flu

$191M (Tom Vilsack, Agriculture Secretary)

Introducing Ultra Safe Technology

What is Ultra Safe Technology (UST)? UST is a revolutionary new line of brooms and brushes with innovative technology that utilizes enhanced bristle security units directly molded to the brush block, removing any gaps or seams while ofering unprecedented bristle retention strength. The hand brushes, deck scrubs, and sweeping brooms each have a unique bristle pattern to optimize function, while spacing between the bristle units makes each tool easier to clean, dry, and inspect. Contact us today for more information.

1-800-826-8302 2 nelsonjameson.com son nja eson.com

00_Food Manufacturing Sept2015_FINAL.indd 10

28/08/2015 20:02

O 2 A YE RS

THE ONLY SHOW you need to attend is in Las Vegas this September. No other trade show in 2015 offers as many state-of-the-art processing and packaging solutions to meet your highest production-line standards as PACK EXPO Las Vegas. More than 30,000 of the most successful manufacturers in the industry will gather in the Las Vegas Convention Center, September 28 – 30, to discover new trends, test new technology from 1,800+ top-tier suppliers and learn from powerful educational opportunities. It’s the only show you need to attend this year—make sure to be there.

R E G I S T E R T O D AY

00_Food Manufacturing Sept2015_FINAL.indd 11

PA C K E X P O L A S V E G A S . C O M

28/08/2015 20:02

FOOD SAFETY Why Food Regulatory Compliance Seems So Complicated and What Can Be Done to Simplify It By James Cook, Food Scientific and Regulatory Affairs Manager, SGS Food Safety Services

For the last decade or more, it seems as though every week there is a new regulation, directive, law or standard for food safety and labeling compliance. For each new notification from the regulatory agencies it seems as though there are hundreds of pages of information to review. There is no inexpensive and readily available source for obtaining a summary for this information. Even when a summary is obtained, the requirements and language are not simple. The government agencies tend to change everything, even when it has been done the same way for decades. In addition to this, customers want more and more transparency of production and regulation compliance information each day. People in many companies are hired just to determine what the compliance requirements are, what needs to be done to remain in compliance and to provide this information to those that are requesting it. The cost of ensuring goods remain in compliance keeps rising, while sale prices do not rise at the same rate.

he reasons that regulation compliance appears to have become more complicated are as follows: We have better data collection today, so we know how, where and when people are becoming ill from food. We are also collecting this information faster. With this information, government agencies can change, improve and add programs to reduce these incidences. This adds to the complexity of the regulatory framework, but after a period of time businesses adjust, so it no longer appears to be complicated. At least until the next change comes along. For example, on May 14, 2015, the U.S. Centers for Disease Control and Prevention reported its Foodnet data1. This data shows that there has been some progress in reducing foodborne illnesses. Shiga-toxin producing E. coli O157 has decreased 32% compared with the 2006-2008 data and 19% when compared to the last three years. The United States Department of Agriculture Food Safety Inspection Service has increased the scrutiny on beef products the last few years. The fundamental devel-

opment of the regulatory change took place over 20 years ago and since then there have been changes implemented to improve the food safety culture. These regulations required HACCP programs and testing. At the point when this was instituted, such testing and certification was complicated for the industry. Now, the industry views this as routine. Each year we have more information on how certain ingredients affect our health. For example, we learned that saturated fats raise the level of Low-Density Lipoprotein (LDL) cholesterol in blood which, in turn, increases the risk of heart disease and stroke. In the 1980s, the food industry replaced many of the saturated fats that were in food formulas with trans fats. Trans fats unfortunately also increase the level of LDL cholesterol in the blood, increasing risk. In 1993, the U.S. government required specific nutritional labeling in order to provide consumers with information allowing them to select foods that are good for them. In 2006, the U.S. Food and Drug Administration required the listing of trans fat so consumers could have more information. Even at

that time, the FDA stated that there was no safe level of trans fats. Recently, the FDA revoked the Generally Recognized as Safe status of partially hydrogenated oils, which are the primary source of trans fats, in order to help reduce incidences of heart disease. The Nutrition Labeling and Education Act seems complicated. A lot of testing and changes had to be made. Now, a large number of countries have some sort of nutritional labeling requirements. In the last 100 to 150 years, society has gone from a local base to a global one.

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 12

n 28/08/2015 20:02

MORE THAN PACKAGING: PROTECTING THE QUALITY OF YOUR PRODUCT Klabin once again has pioneered the industry by becoming the frst Brazilian company to offer industrial sacks recognized by the American Institute of Baking (AIB), which attests to the integrity and sanitary conditions of its sacks and assures consumer health. Klabin’s food sacks feature strength, safety, print quality, easy automation, high packing speed and optimal palletization. Moreover, Klabin’s industrial sacks are biodegradable, recyclable and made from raw materials sourced from forests planted specifcally for this purpose. Certifcations and recognition: Chain of Custody certifcation from the FSC® (FSC-C017793) (Forest Stewardship Council®) Recognized by the Carbon Disclosure Project (CDP) Certifcations: ISEGA, ISO14001, ISO9001 Recognized by the American Institute of Baking (AIB)

00_Food Manufacturing Sept2015_FINAL.indd 13

28/08/2015 20:02

FOOD SAFETY Advances in transportation have made this possible. With this change came new foods, new ingredients and new problems. For example, consumers desire to have these products and ingredients from other countries available in their country. In response, the regulatory agencies have tried nationally to keep pace with other cultures’ accepted

tions for regulatory compliance for many companies seeking to trade their products throughout the globe. For example, the sweetener cyclamates is approved by the Codex2 and many countries of the world but is currently banned in the United States. This is an ingredient that can aid in sugar consumption reduction and provide prod-

…national governments are realizing that the problems regarding food safety need to be rectified on a global scale…not just on a national one… products, ingredients, innovations and adulterations. Of course, no one government can keep pace with these changes. The Codex Alimentarius was established 50 years ago in an effort to keep uniform standards to increase freedom of trade between countries. This has worked to some degree, but unfortunately international attitudes still prevail, which add complica-

00_Food Manufacturing Sept2015_FINAL.indd 14

ucts to consumers, such as diabetics, who can’t consume products with traditional sweeteners. Unfortunately, there are many other products and ingredients throughout the globe that suffer from this regulatory compliance complexity. Fortunately, this uniform standard is working, albeit slowly, because national governments are realizing that the problems regarding food safety

need to be rectified on a global scale, and not just on a national one, as some of these restrictions are not really warranted. This reduces regulatory complexity, allowing local companies to explore the global marketplace. Consumer preferences have gone virtually full circle as society has gone from fresh, local products to processed foods and back to fresh products again. This time, the source is global instead of local. The complication of food safety and import regulatory compliance almost stifles the sale of some products. How does one sell a product in one location where the product is being requested fresh or slightly processed because it is more beneficial, but where consumers lack the knowledge of proper cooking, cleaning or consumption practices of the product and who might suffer from the potential natural hazards of the product itself? On some of these items, regulations have been imposed to prevent entry into a country, or restrictions have been imposed on where these products can come from. Eventually, these restrictions are lifted or circumvented by companies selling these items, therefore simplifying a complex regulatory situation. There are many regulatory restrictions to protect local and national businesses that add to the complexity of the situation. These restrictions are put in place in the name of food safety. Unfortunately for some industries, as soon as one restriction is removed, another is put into place, further complicating the situation. While short term benefits are typically seen by local or national businesses, eventually the product becomes more expensive or less available. As a result, consumers have to turn to other alternatives, reducing the market share for other product lines and sometimes having negative effects on consumer health. Since regulatory complexity isn’t going to disappear, it becomes a matter of simplifying in order to comply with the regulations. The unknown is complicated to all of us, and to tackle the unknown by oneself is difficult. Whether your company is a manufacturer, retailer, importer or distributor, all companies affected by the regulations are in the same situation. This is where band-

28/08/2015 20:02

www.foodmanufacturing.com

ing together in associations and having the same programs is beneficial to all companies involved. These food associations have many abilities. They bring together experts in their particular field and assess regulations to provide feedback to their members in handling specific regulations. They publish summaries and offer presentations to develop an understanding of what needs to be achieved in order to foster regulatory compliance. Even before regulations are published, these associations communicate with government agencies in an effort to try to ensure that they are designed to increase food safety and marketability fairness while minimizing the impact they have on the industry they represent. Government agencies understand that it is not just a matter of publishing regulations that the industry will instantly comply with. There is a realization that education must take place, even while they are enforcing the regulations. Programs such as the Global Food Safety Initiative are designed to develop safe food operations, but also to promote fairness among the operations being reviewed against one consistent standard. These programs were developed by the industry to police themselves, to help their relationship with government, to avoid overregulating an industry that is already trying to resolve the problem, and to indirectly include these programs into the regulatory framework. Third-party industry, whether it be certification bodies, testing laboratories, data or supplier chain management companies, regulatory information companies or others, want companies to expand their programs in order to increase their business. In order to do this, they provide information and tools to their customers to enable them to achieve compliance with regulations. As shown by the discussion between the EU and the U.S. during the process of working out the Transatlantic Trade and Investment Partnership3, protection restrictions are probably the most difficult areas to foster agreement among governments and within industry. With clear agreements about what can and cannot be done, and where or how a particular product can be made, the regulation process can be simplified. With publication of the first fundamental rules of the Food Safety Modernization Act, producers can rest at ease knowing that once the regula-

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 15

tion is understood, and ways to comply with it are shown, the complexity of the situation disappears. While each new regulation seems to be frightening and complex, when we look back at them they are just another routine in the program to provide safety and quality food to the public.

References 1 h ttp://www.cdc.gov/media/releases/2015/ p0514-reducing-foodborne-infections.html 2 h ttp://www.codexalimentarius.net/gsfaonline/ groups/details.html?id=71 3 h ttp://uk.reuters.com/article/2015/07/24/us-euusa-trade-cheese-idUKKCN0PY14B20150724

LOCKED IN FOR SAFETY Integrated Design Points: • Secure Spray Straw Locks Into Place • Convenient No-Slip Grip • Wide Spray in the “Down” Position • Precision Spray in the “Up” Position • Useful Catch Curb

VISUAL IDENTIFICATION LABELING PROGRAM Features: • Color-coded Stickers/Posters • Multilingual Signage • Customizable by Facility

STOPLIGHTFOODSAFETY.COM 28/08/2015 20:02

Spotlight On: FILLING Servo-Drive Auger Filler The Revolution Series Auger Filler is a costcompetitive, ideal solution for straightforward, clear-cut filling applications in the coffee, beverage, food, pharmaceutical and chemical industries. The Revolution Series Auger Filler comes with many benefits – and quickly filling your application tops that list. Features include: • Servo motor precision auger control • Direct drive design • Full color touch screen operator interface • PLC based controls

• Non-proprietary electrical components • In-line check weight feedback • 5g to 5lb fill range • 16 gallon hopper • 6” diameter hopper inlet • 24” x 30” x 12” NEMA 4-electrical enclosure Available options include: • Hopper level control • Off-line check weight feedback with scale • Controls for flapper tooling Spee-Dee www.spee-dee.com

25kg Bag Fillers Company can integrate a precise and accurate 25kg bag filler into your bulk powder processing system. These 25kg bag filling systems comply with food and dairy hygiene standards. The dust-free design allows for a high level of accuracy, sanitation and ease of use. Features include a modular design that allows for flexibility and growth. Company can design a complete powder handling system for packaging dry bulk powders processed in the dairy industry, including infant formulas and nutritional mixes.

High Speed Filling Machines Company’s new series of level filling machines for shelf-stable beverages and viscous foods offers customers an improvement in changeover time and hygienic construction that simply were not available until now. These machines, depending on their configuration, are ideal level fillers for shelf-stable juices and drinks, as well as salad dressing, salsa, ketchup, and other viscous sauces. One of the design breakthroughs of these machines involves adding positive pressure and siphon-like suction to level-filling valves in a two-vessel design. For viscous foods, this design eliminates the need for pistons, which tend to require considerable time to clean and change over when a new container size runs on the line. The two-vessel system also accommodates heated or insulated tanks for filling shelf-stable beverages. Federal Mfg. www.federalmfg.com

Options include: • Single and multiple head fillers • De-aeration, neck stretching and top-up stations • Heat sealing • Bag flattening, kicking, turning • Check weighing and reject systems • Gassing systems • Metal detection • Inkjet printing • Powder sampling Powder Process-Solutions www.powder-solutions.com

Servo Pump Fillers

Servo Pump Fillers are designed with sanitation in mind. These sanitary pumps are CIP – Clean In Place, they sanitize themselves. Not only are there fewer parts to clean, but the front cover plates are hinged for rapid sanitation swab testing. The servo controller makes changeover from one size to another quick and easy without change parts. These servo filling machines feature the latest in controls technology, achieving the highest efficiency with the smallest possible footprint. Fill parameters are tuned to maximize speed, product spread or to eliminate splash. These machines are ideal for products like sauces, dressings, jellies, condiments, macaroni and cheese, fettuccine alfredo, fruit desserts and more. Hinds-Bock www.hinds-bock.com September 2015

00_Food Manufacturing Sept2015_FINAL.indd 16

n 28/08/2015 20:02

MATERIAL MASTER â&#x201E;˘ HANDLING SYSTEMS

Conditioning System

Filling System Sanitary Bulk Bag Discharger O Full or partial

system integration is available

O Designed and built to the

Container Discharger

highest standards with exclusive patented features

O Custom designed to

your specific application requirements

Sanitary Dual Bulk Bag Discharger

O For any size or weight

drum, container, or bulk bag

Sanitary Drum Discharger

World Class Manufacturer Of Material Handling Equipment

Call: 800.836.7068 www.materialtransfer.com

00_Food Manufacturing Sept2015_FINAL.indd 17

Container Discharger

Drum Discharger

Four Post Filler

Discharger

28/08/2015 20:02

Exclusive feature

Track and Trace Technology Yields Benefits for Food Manufacturers By Jack Payne, Ross ERP Product Manager, Aptean

t has been said that there are no tragedies, just facts not recognized in time. This certainly relates to food safety, where delays in knowing the facts can indeed lead to bad consequences, human and corporate, as we have seen from recent events. I’m thinking specifically of the Blue Bell Creameries ice cream recall, something that should have all food manufacturers taking a very close look at their track and trace technology. In food safety, there are two primary concerns: prevention and response. Part of prevention is being prepared. The first Blue Bell recall resulted from a product that had gone into the foodservice channel at a hospital in Kansas. Shortly after the initial recall, other inci-

dents of Listeria contamination emerged, and it was discovered that the problem was happening in multiple Blue Bell plants. Because of the expanded scope, Blue Bell ended up recalling all of its products. In hindsight, a sophisticated track and trace system may have helped mitigate the problem. As the name indicates, the “track” function happens as things occur, “trace” after they have occurred. An effective system executes both functions.

The Benefits of Track and Trace When manufacturers consider track and trace systems, they typically think about the reaction to a problem; but these systems can also help prevent problems from occurring. A good track and trace system records accurate information in a timely manner. The best way to do that is through some type of automated data collection. Barcode scanning is the most popular method. One of the most common reasons for a food recall is mislabeled products. Either an incorrect label is applied or an allergen was introduced into a product as a substitute ingredient and not listed on the product label. By having a track and trace system in place and recording information in a timely manner, many of these incidents can be avoided. Consider salad dressing. Production may attempt to use a substitute ingredient that has a soy allergen, due to a stock shortage, but the operator may not be aware of this fact. As he tries to scan the ingredient into the mix, the track and trace system prevents it from being added. So in addition to track and trace responding after the fact — connecting all the dots in the supply chain — it can also prevent problems from occurring at the point of manufacture. Other examples of the benefits of this process include: • P reventing release of a product not passed by quality control or not having gone through all requisite testing • E nsuring accurate shelf-life by verifying that product going into distribution channels has adequate shelf-life from the point of departure

Best Practices A track and trace system shouldn’t be a “tack on” system; rather, it needs to be integrated into the manufacturing process. A separate system that is bolted on creates significant concerns, principal September 2015

00_Food Manufacturing Sept2015_FINAL.indd 18

n 28/08/2015 20:02

www.foodmanufacturing.com

among them the accuracy of the data, the timeliness of the data, and its accessibility. Track and trace should be core to a food manufacturer’s business system to track every activity that occurs, even prior to receiving goods from suppliers. Then, as goods are received, information about those goods should be recorded and verified. Depending on the nature of goods received, this could include temperature, sanitation data, product characteristics, shelf life, etc. If it is part of the enterprise system itself, a prevention mechanism to reject non-conforming receipts is built-in as part of track and trace.

served as a wake-up call to the dairy and food industry. Blue Bell’s reputation was stellar. Like most consumers in the South, I’ve been enjoying ice cream all my life, and I’ve been eating Blue Bell since it was available in Georgia. That such a respected

company had a problem of this magnitude has caused many dairy and food manufacturers to review their own processes and procedures. And one important requirement they should closely examine is track and trace.

Field Notes One of my customers in the meat industry had implemented a data collection system to scan all information for accuracy as well as efficiency. They hadn’t thought about how the system worked as a preventative mechanism, but found out shortly after implementation. The first week the system was in use, an employee pulled a product for delivery and scanned it, but the system wouldn’t allow its use. Of course, they thought the problem was with the system, but it turned out the operator was (and had been) pulling the wrong product for this customer. This could have been a potential problem; in this case, a higher value product was being pulled and delivered, so the system had an immediate bottom-line impact by correcting the issue. Another customer equipped with track and trace provides intermediate products for leading manufacturers. As it happened, a major customer appeared unannounced for a quality audit, an experience some might equate to having the FDA show up. In this case, the company showed how their track and trace system worked, and the customer was amazed at its performance. The manufacturer leveraged the audit into increased business with that customer, and now sees the track and trace system as a competitive advantage they can leverage to protect their business from competitors as well as increase sales to existing and new customers. They have also been able to differentiate themselves in a commodity-based market and demand a premium for their product. Finally, if there’s a good outcome to the Blue Bell incident, it may be that it has

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 19

28/08/2015 20:02

cover storY

A Leader In Its Field With more than 60 family growers in its co-op, Oregon Cherry Growers is the largest processor of sweet cherries in North America. By Kari Imberg, Associate Editor

o an out-of-state visitor, the rolling hills of Oregon’s Willamette Valley are simply a beauty to the eye. But nestled along the Columbia River Gorge lies an abundance of orchards, where the marriage of warm days and cool nights produces a delectable treat: fresh cherries. Starting out with only 700 rootings, Oregon Cherry Growers has since evolved across generations of dedicated growers into a worldwide supplier of sweet cherries. In fact, with more than 60 family growers in its co-op, OCG proudly wears the title of the largest processor of sweet cherries in all of North America — with Chelan, Sweetheart and Bing as just a few of the 21 varieties grown. OCG has three facilities; two in The Dalles and one in Salem. The downtown facility does the pitting and the vacuum

pan ice cream cherry, while the Riverside facility is primarily used for infusion, drying and freezing. The Salem processing plant is responsible for the co-op’s maraschino, glacé, and some ice cream ingredient cherries. And with its approximate 450 workers, OCG is the second-largest employer in The Dalles. With a name like Oregon Cherry Growers, though, customers may be quick to assume that only cherries are produced — but families of the co-op also grow blueberries, blackberries, strawberries, marionberries, raspberries, saskatoons, and even some vegetables like sweet potatoes, rhubarb and squash.

A Rich History Oregon Cherry Growers was founded in 1984 as a result of two merging cooperatives — The Dalles Cherry Growers and

Willamette Valley Cherry Growers. While OCG is a part of the Northwest Cherry Growers, its orchards are all located throughout the Willamette Valley — the phenomenal fertile grounds between Portland and Eugene, Ore. The Northwest Cherry Growers region runs East of Portland into The Dalles, following along tightly to the Columbia River Gorge, and then up into Washington. “We’ve got two very different growing regions; which is ideal,” Dan Ostlund, director of business development, said. While there is no average time of harvest, the season generally runs between June and August, according to OCG VP of Sales and Marketing Kent Spalding. Ostlund said the interesting thing about OCG is it tends to be more independent family farms as opposed to big corporations. “A lot of farming has become a

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 20

n 28/08/2015 20:02

00_Food Manufacturing Sept2015_FINAL.indd 21

28/08/2015 20:02

cover story corporation and generation to generation farming has gone away. But that doesn’t seem to be the case with cherries,” he said. The company finds great success in being a co-op, as it works to represent each farm individually, bringing through their pride, identity and ownership of the company. “We [OCG] really do work for them. The growers. And they really do feel like that,” Spalding said. “They are the DNA of our company. What the wiring is inside.” OCG’s field services groups are constantly going out to the farms to check the orchards; trying to figure out what the season will hold. “We start to look at what cherries can go into our fresh market versus what will go into our freeze market,” Spalding said. Spalding added that there are many advantages of being a part of its co-op, as OCG brings support to the growers through field services. The company teams up with various universities, like Washington State University and Oregon State University, to give the grower families the latest and greatest on pesticide management, pruning techniques, etc. And it is with the aforementioned partnership with Oregon State University that OCG pioneered the modern day maraschino cherry. With big-name customers like McDonald's, U.S. Foods and Sysco, the

co-op takes pride in being the largest supplier of maraschino cherries to the foodservice arena. Its foodservice segments include restaurants, distributors, healthcare, cash and carry, bars and nightclubs, K-12 schools, universities and military. While also dipping its toes in the respective retail and export markets, OCG’s other main distribution channel is the ingredients sector. With its 21 varieties of cherries, it’s

no surprise that OCG is also the largest supplier for ice cream ingredients. Its customers include Ben & Jerry’s, Dreyer’s, Breyers and Blue Bell, just to name a few. “You pretty much name the brand and we are the primary supplier for that,” Spalding said. Oregon Cherry Growers’ ingredients can be found in consumer products like ice cream, dairy, bakery, cereal, and baked and slab bars. As for its retail line, the company has been strategically focusing on expanding that market. “Through history, our business has been primarily focused on the foodservice side and the industrial ingredient side,” Spalding said. “So now what we have done is, we took a look at maraschinos on the retail side and really started to ask some kind of consumerfacing questions.” From fruit preps and purees, to maraschinos, to its new Royal Harvest line of cherries, blueberries, strawberries and other dried fruits, OCG offers an array of fruit products made with high-quality ingredients. Made with all-natural, non-GMO ingredients and Fairtrade cane sugar, its Royal Harvest line of premium dried fruits have become a favorite among healthconscious consumers. The line of ready-to-eat dried fruits drew praise at the 2014 Oregon

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 22

n 28/08/2015 20:02

www.foodmanufacturing.com

Manufacturing Awards ceremony last fall with OCG receiving the Product Innovation of the Year award. The Royal Harvest line was recognized for its proprietary drying process, which helps to protect the natural sweetness of the fruit, as well as maintain the moisture and texture content. OCG President and CEO Tim Ramsey said the company saw an opportunity to grow, so it started a new product line to help fill that gap. “The dried fruit segment of the food industry is a $50 million business annually and it was a significant opportunity for us,” Ramsey said. He also added that the co-op is continually looking for new ways to deliver a highvalue return to its family growers. So far, the Royal Harvest fruit has seen a strong response from bakeries, chefs and other food professionals looking to include the fruits in their own products. But developing new products is just one way that Oregon Cherry Growers is meeting the demands of a changing food industry. In a typical grocery store today, you will find a jar of maraschino cherries that holds around 20-25 cherries. But after the team did some research, OCG concluded that consumer usage is really only about 6-10 cherries. After some probing, OCG found that the average consumer keeps maraschino cherries in their refrigerator for one, two and even upwards of three years. Spalding added that the positioning of maraschino cherries in the grocery market is over in the canned fruit aisle, so it’s not really located where all the usage occurs. “If you’re making an ice cream sundae or want to use it in baking or you want to use it to make your Manhattan drink, you have to work pretty hard to find it in the grocery store.”

pany to unveil its latest innovations — this time in packaging. The new, convenient pouch-style packages are the first of their kind and have already received the National Restaurant Association FABI Award this past March. Spalding said they wanted a solution that was not only beneficial to the consumer, but also to the retailer. “That’s when we came up with the idea of putting maraschinos in pouches,” Spalding said. “So what you can do is you can peg them, you can clip-strip them, etc. In a retail environment, that shelf-space is very precious, so they’re constantly looking to say ‘Okay, what’s the best return and what fits the consumer need?’”

Spalding said the pouches allow retailers the opportunity to sell something that perhaps they weren’t going to before. With two different size pouches, an 8-count and a 16-count, the company sees the pouches as a way to match packaging in a delivery vehicle with consumption patterns. OCG has also recently introduced new packaging on the distributor side of its business. The company began to look at the interaction bartenders have with cherries and found that the current usage of gallon and half-gallon containers was a sugary, sticky mess — leaving bartenders with the option to either spoon the cherries out or use a glove to grab them by hand.

A New Age It was those findings that led the com-

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 23

28/08/2015 20:02

cover story With time and speed being the two most important factors for bartenders, OCG decided to improve upon this. “We can provide a value to these folks that allows them to do their jobs more efficiently,” Spalding said. “We can solve sanitary issues and ultimately save them some money on operating costs by not having to refrigerate giant gallons of cherries.” The solution? Cherries in a pouch. With a notch that allows bartenders to tear it open and dump the cherries into a bar tray, OCG has answered the sticky mess. The pouched cherries still go through the same safety mechanisms, such as pasteurization and handling, but it now allows bartenders the opportunity to grab cherries quickly. Spalding said the response so far has been “phenomenal” as the bartenders realize the convenience of the new method. “We’re pretty excited about this because it's two pieces of innovation mostly around packaging, but it’s in an industry that hasn’t innovated for over 80 years,” Ostlund said. “It’s an opportunity for us to really do things better than they have been doing in the past.”

Rising to the Challenge With its history deeply rooted in manual labor, the majority of the growers still pick their crops by hand. And with 10,00012,000 tons of cherries going into the fresh market every year, that puts a lot of strain on the co-op. Ostlund said the PNW cherry growers is still very much a part of a labor-intensive process, but the industry is starting to shift. Currently, the cherries (and other fruits) are both picked and sorted by hand. And as anyone in the cherry business can tell you, cherries selected for the fresh market must be flawless. OCG has begun to improve its sorting techniques in its fresh lines by the addition of its automated optical sorting machines. The technology is able to more precisely sort the cherries, specifically by size and defects, allowing for a better payment to the grower. Ostlund said there is a much smaller chance for missorting with machines, compared to manual labor. While electronic sorters that accurately size and sort for internal and external defects have been available for round

fruits like apples, citrus and kiwis for many years, it’s new to the cherry industry. The hold up, of course, was the stem. It was difficult to manipulate the stem so that cameras could see all sides of the fruit, but the new computerized sorting technology uses infrared or high-resolution cameras to take multiple pictures of a single fruit. “With people sorting, they missort some or you don’t get the right size,” Ostlund said. “But with sorters, they get the exact size that’s the larger size that can go to a perfect market like export, they’ll get a higher dollar for that. And they’re going to get more cherries because they’re not missorting out anything.” He added that from a processing standpoint, new equipment can help to cut down on overhead. The sorters are expected to change the dynamics of the cherry industry, something Ostlund said is needed in order to keep up. And this year, the technology came in handy as OCG experienced a smaller 2014 crop due to freeze damage. Temperatures crashed as much as 60 degrees in just a few days in mid-November, killing 1-, 2and even 3-year-old wood in cherry trees. It affected growers differently, depending on their location. While Salem and other parts of the Willamette Valley escaped much of the damage, many growers in The Dalles region were hurt by the colder weather. Having the optical sorters in place allowed for growers to save any cherries in a timely fashion.

“Anytime you’re working with Mother Nature, you just never know the outcomes,” Ostlund said. “I mean we could have just an absolutely perfect growing winter, delightful spring and then at the last minute when the cherries are forming on the trees, there could be a problem.” As for its plans for the future, Ostlund added that the current processing facilities are still meeting the demands of the more than 44 million pounds of cherries processed annually. “We are revamping the downtown facility to accept fresh cherries in and really sort them for our whole freeze market. So we have brand new equipment there, too. So we are taking our existing buildings and just upgrading them,” Ostlund said.

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 24

n 28/08/2015 20:02

Your operation is full of unseen risks. Risks that could lead to food contamination and costly downtime. Clarion ® Lubricants can help you identify those risks to protect your bottom line and your reputation. To learn how we can help you develop a lubrication program that optimizes maintenance and safety, visit us at clarionfoodsafety.com.

00_Food Manufacturing Sept2015_FINAL.indd 251 66546 Clarion_Food_2015_1Question_Adv.indd

clarionfoodsafety.com

28/08/2015 20:02 7/28/15 2:08 PM

5191_66546_BVK • Clarion • 1Question Food Grade Ad • Advantage Business Media 8”x10.75” • 7/28/15

Questions

Answers

With Camilla Howard, Marketing Manager, Unitherm Food Systems

Interview by Jesse Osborne, Editor

Food Manufacturing spoke with Camilla Howard of Unitherm Food Systems about the topic of thermal processing in the food manufacturing industry.

Q. What are the newest

innovations in thermal food processing technologies?

A. Flame peeling onions. The

statistics alone in this new process are what caught my attention: Processing time 45-60 seconds, loss of 2 percent. My background is working in kitchens, particularly in smaller restaurants where minimizing waste is a focus. So I wasn’t surprised to learn that yields were sacrificed for efficiency when automating this process. Traditionally, onions are topped, tailed and peeled, resulting in a loss of about 20 percent or more. This new patent-pending approach was inspired by flame roasting peppers, which is essentially done by charring the skin and washing it

off. Unitherm has used the body of the traditional flame grill and radically changed the internal build with intellectual property to fit this new application, the Flame Peeler. Beyond the benefits of yield improvement, the new process also pasteurizes the onions. The system is already installed and operating in Australia and America.

Q. What trends do you see

in consumer preferences regarding processed foods and how are processors addressing those preferences?

A. As a society we’re shift-

ing from a culture that eats solely for pleasure and flavor, to a focus on health. Healthier diets and lifestyles

are “trendy.” Since public knowledge of health risks and benefits associated with foods are more readily accessible and visible, consumers are informed. As a result, demand for food to not only taste good but to also achieve specific health parameters is growing and evolving on a daily basis. Interest in products that are healthy, low sodium, fresh, or next tier and artisanal insinuate health benefits. Consumers are watching not only caloric intake but sodium levels, sugar levels, ingredient lists, extensive shelf-lives, stabilizers, etc. Where in the past food manufacturers have focused on producing sales as a result of taste, gears are shifting. Plant managers have to meet the demands of both their management team, watching their bottom line, and research and development teams pushing for innovation and market relevance. So more and more processors are looking for ways to add value to their products while achieving health demands put forth on the market. How can a product taste good, without oversalting? How else can flavor be extracted? Perhaps with various other spices, or using different cooking applications and methods. Grilling, for instance, to add barbeque flavor and appearance. Flash frying and baking, rather than deep frying products. Achieving pasteurization through thermal energies, with the use of infrared technologies

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 26

n 28/08/2015 20:02

Questions

Answers

instead of injecting ready to eat deli meats with antimicrobials. Or the use of liquid smoke combined with infrared grilling to eliminate carcinogens. In the past six months alone we’ve seen a significant shift in this direction; flame grills have been in high demand, customers are searing and bar marking to add flavor naturally to products, before sous-vide cooking. Usually the benefits are two-fold: the products are healthier for consumers, but also the producers themselves see benefits to their bottom line.

Q. How can food manufacturers/ processors benefit from working with thermal food equipment manufacturers to achieve their goals?

A. Just as food processors are

experts in their field, with their products and perhaps on their processes, such is the same for equipment manufacturers. Once a goal has been identified and disclosed, we know what alterations to make to achieve these goals. This may be through the use of a current model of equipment or the creation of something new. For food manufacturers, this might mean considering a whole different approach; instead of perhaps their traditional cooking method using rack ovens, they might be encouraged to change to a continuous system. The new system may involve different thermal energies that food processors otherwise may not have combined to generate the desired results. When two teams from different fields come together and collaborate openly to achieve a common goal, both parties benefit.

Q. In your opinion, what single

thermal food solution can diversify a product line from generic to an added value product?

A. A direct-flame grill. More

specifically, I can speak from experience about a Unitherm Flame Grill. This equipment can take an anemic, generic product (be it a chicken breast or zucchini) and in seconds provide

flavor, color and yield improvements. The flame grill, though often sold as part of a full processing line, can function as a stand-alone unit, so it can apply to various levels of processing. It can be integrated to the front of a full

in the market for a new piece of equipment. At Unitherm we look for this opportunity, identify it and find a solution. The HACCP at each processing facility varies, but the goal is the same — reduce risk. In January, Unitherm

The flame grill is a great accessory to these processing lines, developing color and flavor first. We have several Michelinrated chefs in love with this piece of equipment… cook line, finish a line, or even be used in a partial cook line. In the last year we’ve seen a huge growth in sous-vide cooking applications. The flame grill is a great accessory to these processing lines, developing color and flavor first. We have several Michelin-rated chefs in love with this piece of equipment through their collaboration with food processors. The combinations and applications are endless — and the results speak for themselves.

collaborated with the Grote Company to eliminate a highly volatile point in any processing line — bacteria growth on slicing equipment. After identifying the risk, the solution seemed simple — and through collaboration execution was possible. In short, it’s a self-sterilizing slitter that attaches to the end of the cooking apparatus, slicing while the product is still hot, and simultaneously sanitizing the blades; virtually eliminating risk.

What are equipment manufacturers doing to aid food processors as both consumers and regulators evolve, increasing demands and challenges?

A. As demands increase for food

processors, equipment manufacturers have to be agile enough to adapt with them. These demands can be viewed as hindrances or opportunities. When consumer demands change, processes need to be altered. This provides an opening

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 27

28/08/2015 20:02

Exclusive feature

Equipment Maintenance: Food Manufacturing’s Secret Ingredient By Heather Betts, Maintenance Site Manager for Advanced Technology Services

quipment design, quality control, skilled labor — the list of essentials for efficient food manufacturing is long. But many managers don’t fully consider one factor that arguably has as much to do with production efficiency as any other variable: equipment maintenance. The food industry faces challenges that make equipment maintenance uniquely critical. With new food products coming to market faster and more frequently than ever before, CPG companies must constantly add or modify equipment; this imperative strains maintenance staffs who must keep equipment running despite the changes. Also, food production technology continues to evolve. Nearly two-thirds of food processing plants are more than 20 years old — and the cost of keeping up with production advancements is causing food manufacturers to invest more in capital equipment than nearly any other industry. Lean manufacturing and other continuous improvement disciplines are finding their way into more food manufacturing operations than ever before, placing huge emphasis on machine maintenance. Production standards and tolerances are also impacted by external mandates, not only from state and federal regulations but also industry standards like the Global Food Safety Initiative (GFSI) and FSSC 22000. On the business side, large CPG companies insist on consistent quality across their plants, large and small — while smaller manufacturers need to keep up with their competitors. Finally, production operations are continually impacted by mergers and acquisitions that force frequent changes in manufacturing equipment. Amid all these challenges, food manufacturers must keep their equipment running smoothly, efficiently, within tight standards, and without expensive downtime. So important is maintenance to profitable operation, in fact, that it helps to frame the issue not simply as maintenance but as an “equipment reliability program”— a term that much better captures its true value.

An equipment reliability strategy is the result of a series of steps that identify, prioritize, and execute those tasks needed to keep a production facility operating at peak efficiency at minimal cost. The first step is to identify the critical equipment; while it may appear that every machine is important, in all manufacturing operations there are constraining machines that, if offline, will cause major production slowdowns or even stoppages. Equipment should be ranked in order of criticality, with those at the top receiving highest emphasis in terms of upkeep, quality checks, failure analysis, and repair or replacement parts. Next is an evaluation of the existing maintenance program. The evaluation should identify all procedures, including parts programs, recordkeeping, and workflows that support the maintenance effort. Special emphasis should be placed on work orders for the repair or replacement of key items that can bring down a machine. Maintenance staff should check these records each month; if failures to these machines are still occurring, it could be a sign that orders aren’t being placed or addressed in a timely manner. Once the inventory tasks are complete, it’s time to consider a comprehensive maintenance approach. There are three primary ways to approach equipment maintenance: Run-to-Failure, Preventive Maintenance and Predictive Maintenance. The first, Runto-Failure, is actually a defensible strategy

if the cost of maintenance is greater than the cost of unexpected failure. More often, however, a combination of preventive and predictive programs are warranted. Preventive Maintenance (PM) represents the time-directed approach to reliability. It mandates inspection, diagnostics, service, and parts replacement according to wellplanned and timely schedules. Because PM is schedule-based, it works especially well in food manufacturing. For example, where multiple processing lines are coupled with packaging/filling lines that are run intermittently, there are natural opportunities for PM when such lines are not in operation. It’s important to note that because PM calls for work to be done by schedule, it may result in tasks that are executed where wear has not occurred. Production is often slowed due to drops in consumer demand or other business reasons, yet maintenance staffs continue to service equipment on original schedules. Also, PM may take technicians away from equipment that is close to, or experiencing failure. Predictive Maintenance (PdM), in contrast to PM, is the condition-directed approach. It relies on sensors and asset performance management software to identify maintenance issues before problems occur. PdM is especially important in places where equipment downtime is unacceptable, where risks to product quality are imminent, and where replacement costs are high. Predictive Maintenance also can result

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 28

n 28/08/2015 20:02

www.foodmanufacturing.com

in long-term savings, especially when combined with PM activities. Many Preventive Maintenance tasks can’t be justified on a cost basis — research has shown that as many as 30% of all preventive tasks can be eliminated through the use of PdM. Correct decisions on PM, PdM and Runto-Failure can be made through failure analysis. Advanced exams of equipment and their failure points will produce insights that inform effective maintenance schedules. Maintenance specialists will employ Reliability Centered Maintenance (RCM) analysis, a structured approach to identifying machine tool subsystems, to establish safe minimums for maintenance. Inspectors will also perform Failure Mode Effect Analysis, which looks at potential failure points, to determine how to mitigate failures. An important aspect of equipment maintenance, one that RCM is designed to uncover, is critical spares. The goal for critical spare parts planning is to maximize efficiency; if a part is readily available from a reliable vendor on a timely basis, for instance, it’s not necessary to stock it in house. RCM will also reveal the hidden failures that are not normally observable or considered. Just as most people don’t look at the condition of the spare tire in their car’s trunk, hidden failures can turn a minor problem into something much more consequential — and expensive. The last step in a comprehensive equipment reliability strategy is how to minimize intrusive maintenance. It’s important to realize that PM can sometimes result in accelerated failure of the part in question, or in adjacent parts. If a technician has to take off covers or subassemblies to examine a part, the disassemble/reassemble activity can potentially increase the likelihood of a future breakdown. In such cases, non-invasive predictive tools should be used. Ultrasound detection, infrared thermography, oil analysis, vibration analysis, and other procedures can reveal the health of a system or component part without compromising its lifespan. Proactive equipment maintenance programs have been shown to result in significant cost reductions, with some manufacturers tracking savings as high as 80%. Furthermore, a proactive approach results in a more reliable, more productive food manufacturing environment — one in which even greater process efficiencies are possible. Working with a qualified outsourcer can simplify the task of maintaining equipment,

00_Food Manufacturing Sept2015_FINAL.indd 29

and at a reduced cost. Finding and retaining a qualified maintenance staff can be difficult, not to mention the investments associated with ongoing training. Top-quality outsourcers can increase production asset performance by 30% or more; in fact, in one Grant Thornton study, nearly 14% of food manufacturers surveyed were outsourcing their maintenance operations. With all the responsibilities of meeting routine production requirements, manufacturing managers often don’t consider the cost associated with equipment failures. Yet

Goff_FMMad_815.indd 1

every time a machine goes down, thousands of dollars in lost production can result. Just as important, intangible costs such as ontime shipping and the possibility for lost business also result. With so much at stake, managers are wise to address maintenance efforts in a coordinated manner, either through outsourcing or a well-planned internal effort. As a recipe for improving operations, equipment maintenance is the small ingredient that can make a big — and profitable — difference.

8/17/15 3:26 PM 28/08/2015 20:02

PACK EXPO Las Vegas 2015

It’s the Final Countdown for FSMA Compliance Food manufacturers and equipment suppliers turn to new solutions as compliance deadlines near. By PMMI

hen President Obama signed the Food Safety Modernization Act (FSMA) into law in 2011, FSMA’s 2015 and 2016 compliance deadlines seemed far away. Now, time grows short for food and beverage brand owners to harmonize their operations with resulting regulations. FSMA’s first set of new rules, which governs preventive controls for human and animal food, took effect Aug. 30, 2015, with compliance required within one to three years, depending on the business. The first legislation of its kind in more than 70 years, FSMA was designed to help federal regulators prevent food safety incidents before they occur, rather than react to incidents after the fact. This fall, PACK EXPO Las Vegas (Las Vegas Convention Center; Sept. 28-30, 2015) will feature exhibitors that have been proactive in their efforts to get ahead of the historic legislation.

First, a Recap “The compliance deadlines have been on everyone’s minds the past few years as FSMA nears finalization and full implementation,” said Kyle Thomas, Strategic Business Unit Manager at Eagle Product Inspection. “Compliance with these rules is mandatory by the end of 2016, so food manufacturers need to actively prepare for the enforced regulations if they haven’t already started.” FSMA gives sweeping new regulatory and enforcement powers to the U.S. Food and Drug Administration and affects nearly every link in the food supply chain. It was imperative for packaging companies, which represent a critical line of defense in the battle against food contamination and foodborne illnesses, to begin preparing well in advance. The preparation was critical not only for themselves and their clients, but also for the consumer. Salmonella, E. coli and listeria outbreaks have had adverse effects on

public health and put consumers on edge. According to the U.S. Centers for Disease Control and Prevention’s latest report on trends in foodborne illness, “Foodborne infections continue to be an important public health problem in the United States and highlight the need to move forward with preventive measures.” The agency estimates that foodborne illnesses affect one in six Americans every year. That amounts to 48 million people falling ill, including 128,000 hospitalizations and 3,000 deaths. As part of the overall effort to bring those numbers down, “Food manufacturers must maintain records of internal audits, safety plans and recalls,” Thomas said. “The FDA can request any of this information, set corrective action, demand product recalls and financially penalize where appropriate. FDA inspections of plants are mandatory every three-to-seven years, depending on facility risk. Food safety plans must be written, hazards analyzed and controls created to prevent failure.” Eagle is contributing to the packaging industry’s readiness for FSMA with innovations such as its SimulTask PRO Image analysis software, which comes standard on every x-ray machine the company sells. The software detects and rejects products with contaminants and defects while simultaneously verifying seal integrity, fill level, mass measurement and component count across different production lines and products

without the need for manual changeovers. Users can access reports and statistics on inspected products and its verification tools assist compliance with hazard analysis and critical control points (HACCP) and preventative controls required by FSMA.

Solidarity and Anticipation Morris Packaging also aims to stay ahead of the FSMA curve. The company, which makes corrugated containers, containerboard and poly bags for a wide variety of applications, recently built a brand-new facility in Jefferson City, Missouri. While FSMA calls for a mandatory inspection schedule, how the inspection regime applies to the packaging materials and container manufacturers used by food processors is unknown. However, the new facility, in operation since the end of April, was designed to pass any audit associated with the law. “FSMA doesn’t just affect one company, but thousands. So we started on our building in July 2014,” said Brian Steinwager, Vice President, Morris Packaging. “We’re not sure where it’s going to end up for

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 30

n 28/08/2015 20:02

Gentle Clean Quiet Reliable Conveying

Drive Unit

Horizontal Transfer

• Continuous State-of-the-Art Research & Development • Over 40 Years of Tubular Cable & Disc Technology Conveying Experience • Over 30,000 Conveyors Installed • More Than 65 Countries Served • Starts & Stops Under Load

(641) 673-8451 www.cablevey.com Cablevey is a registered trademark of Intraco, Inc. 09/2015

00_Food Manufacturing Sept2015_FINAL.indd 31

28/08/2015 20:02

PACK EXPO Las Vegas 2015 packaging companies, and we might not know for three to five years, but we’re planning for the most extreme conditions.” Steinwager added that company owner Jim Morris, who also owns ingredient company Heartland Supply Company, has firsthand understanding of the urgency behind FSMA compliance. Through his involvement with the Grocery Manufacturers Association and the Food Ingredients Distributor Association, Morris assisted with the regulations guidelines for FSMA. Steinwager said Morris Packaging’s efforts to fall in line with FSMA well ahead of schedule have not gone unnoticed by its customers. “We’ve had very positive feedback from customers regarding the new building and how we are getting out in front of FSMA,” he said. “From their perspective, it’s one less thing they have to worry about.” For leading processing and packaging solutions supplier Bosch Packaging Technology, preparations for the implementation of FSMA regulations focused on designing equipment to meet anticipated customer needs.

“Under the new FSMA regulations, food manufacturers will be required to identify hazards associated with their applications and to prepare and provide Hazard Analysis and Risk-Based Preventative Control Plans,” said Bosch Product Manager Paul Garms. “When selecting equipment to meet FSMA standards, food manufacturers need to consider packaging machinery with the necessary hygienic design for their application. Utilizing hygienic packaging machinery can significantly reduce the risk of physical, biological or chemical contamination being introduced to the food product.”

Integration and Enhanced Robotics Wes Garrett, Packaging Integration Account Manager for FANUC America says his company is on track to comply with FSMA. “FANUC’s integrators and end users are specifying equipment to meet the requirements of the act,” he said. “In most cases, the deadlines should be achievable.” FANUC specializes in solutions for

For better batching start with

A BETTER BATCH MIXER Our batch mixer uses a double ribbon agitator mounted with solid spokes to a solid shaft for outstanding mixing and blending. The shaft mount reducer drive eliminates the sprocket and chain arrangement to simplify maintenance.

PROCESSING THE INGREDIENTS FOR SUCCESS

+1 (616) 374-1000 • www.apecusa.com

00_Food Manufacturing Sept2015_FINAL.indd 32

robotics, CNC systems and factory automation, manufacturing serial-link and delta-style robots capable of handling any food or beverage application, from raw to packaged material. It was vital for the company to change how it builds its products to help food processors make a smooth transition. “Our integrators need to work closely with customers to deliver compliant systems for the end users to pass inspections,” Garrett said. “It also means that a lot more stainless steel will be required to comply.” FANUC continues to develop new robot variants with secondary food grade capabilities and higher ingress protection (IP) ratings to meet customer demands. These robots include FDA-compliant material and surface finishes. Changes to the FDA’s rule governing hazard analysis and risk-based preventative controls will require companies to self-monitor more than ever before. Robot manufacturers like FANUC will need to ensure compliant material and surfaces during development. Because of the additional scrutiny that FSMA standards apply to packaging companies and packaging machinery makers, customer education will also be critical to the compliance process. “Integrators,” Garrett said, “will need to be sure to specify, order and apply the correct robot variants and options for the application required.” Another robot supplier, Omron Automation & Safety, has revamped its offerings specifically with FSMA in mind. “It’s a whole new ballgame,” said Omron Industry Marketing Manager Laura

28/08/2015 20:02

www.foodmanufacturing.com

Studwell. “We have an entirely new set of products that are better suited for meeting FSMA requirements.” The company’s new IP69K delta robot is one example. Omron added the technology to its portfolio in order to satisfy growing demand for solutions that enhance automation further upstream in the packaging process. The IP69K robot is designed to handle raw materials and food that could contain foodborne illnesses. Its high-speed, toploading, pick-and-place capabilities are also well-suited to chemical and pharmaceutical products, and its smooth, rounded, bolt-free surface means it’s especially easy to clean and sanitize. “The nice thing about robots is that, when regularly washed down and properly cared for under a HACCP plan, they don’t present the challenges that people do on the line,” Studwell said. “They don’t have hair that can fall out or bodily fluids like tears, sweat and blood. A robot doesn’t have any of those uncontrollable human attributes that can jeopardize product safety further upstream in food manufacturing.” Omron’s new robot can also hold up under powerful sanitizing processes that will be necessary to comply with FSMA. Designed to withstand a harsh washdown, the IP69K robot is equipped with a fully enclosed system for gearboxes, servo motors and cables, preventing water ingress. “The whole point of FSMA is to get rid of foodborne illnesses,” Studwell said. “Companies will need harsh wash-down equipment in their facilities, or they’re going to continue to have holds and recalls.”

ees have to go to the wash station before they go onto the floor.” Garrett concurred that the investment in the future of food safety has been significant for FANUC as well. “As the manufacturing costs are driven up, we try to pass as little as possible to our customers,” he said. “It is important to keep robotic automation a viable option for food manufacturers.” He knows the upgrades that stem from FSMA compliance serve a greater good. “With improved monitoring plans and

increased inspection frequency, consumers ultimately get better, safer, uncontaminated product,” Garrett said. Despite the substantial changes and challenges, technology suppliers look forward to the finalization of the FSMA regulations with optimism. With much of the toil behind them, industry players are ready for a new era in food safety. “It’s going to make us better,” said Steinwager. “I would hope it will make everybody better.”

Investment and Reward A wide range of solutions for compliance with standards generated from FSMA can be found at PACK EXPO Las Vegas. As these suppliers roll out solutions to anticipate customer needs, many can empathize with the hurdles food processors face. With regard to Morris Packaging’s new facility, Steinwager noted the significance of the company’s investment. “It cost a lot of money,” Steinwager said. “The concrete and steel cost more than actually laying the concrete. We polished it and sealed it, so we had no open, porous concrete. The inside of the building is fully sealed so we can steam-clean it. There are also wash stations for shoes, and employ-

Booth C-1847 800.397.8664 • www.Dorner.com/FMM

September 2015 Dorner_FoodMfg_Island_615.indd 1

00_Food Manufacturing Sept2015_FINAL.indd 33

6/1/15 6:37 AM 28/08/2015 20:02

product review XPdius i-130 Vertical Form and Seal Machine The XPdius® i-130 vertical form and seal machine is designed to reduce cost of ownership. The XPdius has many tool-less features that save time when loading film, replacing pull belts and doing bag width changeovers. The design allows for complete accessibility to the mechanics of the machine. Access the front, back and inside of the frame easily and comfortably. Capable of running 130 bags per minute while producing a 4.25-inches long bag, the XPdius i-130 is equipped with two Panasonic servo motors and drives. These drives assure total control over acceleration, deceleration and positioning. Standard features include a cantilevered air film shaft that eliminates side chucks to hold film in place. Reload time of new rolls of plastics is extremely fast compared to the conventional film shafts that are supported on both sides using side chucks to hold the core in place. A splicing table with film clamping is a standard feature. This feature eliminates the film running out and requiring threading of the film through the rollers. WeighPack www.weighpack.com

MECHATRON 3-A Sanitary Feeder The MECHATRON® 3-A feeder was designed specifically for use in food and dairy industry process applications where equipment must meet 3-A sanitary levels or equivalent. All welds, radii, seals, surface finishes, gaskets, and contact and non-contact materials meet 3-A standards. Available product features include AC and DC drive packages, an FDA / USDA accepted “Coni-Flex™” flexible conical feed-hopper, helix configurations for feed rates from 0.30 to 330 cubic feet (8.5 to 9,300 liters) per hour and an unmatched ability to disassemble, clean, reconfigure, and service from the nonprocess side of the feeder. A domed hopper cover and open bottom frame speeds and optimizes draining during and after wash-down cycles. Smooth, crevice-free product contact surfaces at 32 micro inch or better help prevent the formation of bacteria. Company also offers industrial grade versions of the MECHATRON® in low, mid, and high range models with feed rates from 0.002 to 1,137 cubic feet (.58 to 32,160 liters) per hour. Schenck Process www.accuratefeeders.com

Food Grade Lubricants Company has expanded its portfolio of Food Grade Lubricants with a range of specially formulated solutions developed for safe use in the food and beverage industry. The newly introduced lubricants are approved to NSF and USDA H1 standards and can deliver excellent lubrication properties to resist wear, friction, corrosion, and oxidation in critical asset applications. Operations can benefit from increased efficiencies and reliability, reduced energy consumption, minimized maintenance requirements, and extended service life even for assets performing under the most stringent conditions. The lubricants additionally can support HACCP processes to contribute toward improved safety in applications plant-wide. The expanded range of Food Grade Lubricants includes LGFP 2 General purpose grease, LGFD 2 High load grease, LGFS 00 General purpose grease, LGFT 2 High temperature grease, LGFC 1 Low temperature grease, LFFM 80 High moisture chain oil, LHFP 150 General purpose chain oil, LFFT 220 High temperature chain oil, LDTS 1 Dry film lubricant, LFFH 46 Hydraulic oil, LFFH 68 Hydraulic oil, LFFG 220 Gear oil and LFFG 320 Gear oil. SKF www.skfusa.com

ID Grippers This company has introduced a robust new series of ID grippers with an 8–85mm diameter range and high holding force that can be adjusted to individual workpieces via feed pressure. Color-coded to correspond with clamping positions for pushed and drawn parts and featuring strong elastomer bellows made of EPDM or silicone, the latter of which is FDA approved for direct contact with food, the new single-acting, pneumatically operated expansion grippers gently grip the inner contours of workpieces without leaving any marks, providing an effective alternative to suction cups and sprue grippers for parts with holes or recesses. Made of high-strength, anodized aluminum and service-friendly EPDM or silicone bellows that are capable of withstanding temperatures up to 130°C (266°F) and 200°C (392°F), respectively, and can be easily replaced in a non-destructive manner if necessary. FIPA www.fipa.com September 2015

00_Food Manufacturing Sept2015_FINAL.indd 34

n 28/08/2015 20:02

Perfection is the Recipe for Success

Perfecting Particle Size The Sturtevant Simpactor® FID pin mill is a USDA type mill that can save up to 50% of capital cost compared to traditional designs. Dry powder food ingredients such as preservatives, sweeteners and more can be milled to a uniform fne particle size of 50-200 mesh (300µm-75µm).

• Minimizes material buildup and food contamination • Quick access to clean mill, no tools required, no dead zones • Wash down design for simple maintenance

348 Circuit Street Hanover, MA 02339 • Phone: 800.992.0209 • Fax: 781.829.6515 • sales@sturtevantinc.com

www.sturtevantinc.com

00_Food Manufacturing Sept2015_FINAL.indd 35

28/08/2015 20:02

Bin Measurement & Mapping for Accurate Volume

Non-contact, dust-penetrating sensor measures and maps multiple points across irregular material surfaces

ACCURATE VOLUME IN DUSTY BINS • Accounts for uneven topography, cone up or down conditions when calculating volume • Provides an optional 3D visualization, so you can see high and low spots or sidewall buildup • Sends high, low, and average levels and a volume calculation to PCs on your network • Reliable performance in four, sugar, meals, or other solids with excessive dust • MultiVision software lets you view all of the bins at your facility in real time

product review Simpactor Food Grade Pin Mill The Simpactor® FID is a specifically designed USDA-type impact mill for milling dry food ingredients to precise fine particle sizes of 50-325 mesh. This mill has the convenience of onthe-fly adjustment of your product size. The rugged design requires minimal maintenance because there is no sizing screens that blind or tear. The Simpactor FID comes in a variety of designs to mill products such a sugar, pet foods, salt and other general food applications. Features and benefits: • USDA type mill: Save up to 50% of the capital cost compared to accepted designs • Eliminates material build-up and food

contamination with no dead zones • Easily disassembles by hand without tools, for cleaning • No screens to blind or tear • Low pressure wash down design. Sturtevant www.sturtevantinc.com

Automated Box Chilling System Designed and built to USDA requirements, the DRI PACK chilling system is ideal for meat packing plants as well as poultry and seafood operations, and is intended for use with new or existing packaging operations. The automated chilling system quickly fills boxes (up to about 24 inches wide) with CO2 snow as they travel along a conveyor. With the DRI PACK system, extremely cold CO2 snow quickly chills the food product, locking in moisture and preserving freshness and quality. A controlled flow of CO2 snow is directed into containers or boxes at temperatures of negative 109.3° F (minus 78.5° C). Once in the container, the CO2 snow does not melt; rather, through the process of sublimation, the CO2 provides the refrigeration to chill food — so there is never any liquid. Linde LLC www.lindeus.com

Tornado T2 Rotary Lobe Pump With low pulsation and wear, the TORNADO T2 is available in a variety of sizes ideal for food industry applications. The all-metal TORNADO T2 conforms with food safety and FDA food processing requirements stipulating that all metallic pump components coming into contact with the delivery medium are made of stainless-steel and offers a high-quality pump solution for sanitary processes. The TORNADO T2 features a maintenancefriendly design, with no need to dismantle pipework or disconnect the drive for servicing. Physical separation of the pump head and bearing housing improves uptime, and the pump’s small footprint improves site utilization. The rotary lobe pumps are ideal for meeting the need for hygienic processing of sensitive food industry products. The pump is available in a variety of sizes delivering quantities of 2,113-36,980 gallons per hour (gph), or 8-140 cubic meters per hour (m³/h). NETZSCH Pumps and Systems https://pumpen.netzsch.com/en/ September 2015

00_Food Manufacturing Sept2015_FINAL.indd 36

n 28/08/2015 20:02

classifieds DynaClean Vertical Z Conveyor The DynaClean Vertical Z Conveyor is an ideal solution for food processing facilities that have a need to move product to higher elevations. The patented DynaClean line of conveyor systems are designed for ease of cleaning and sanitizing, which results in shorter downtimes and the ability to quickly return the conveyor to the processing line. The Vertical Z is custom designed to your desired height and includes widths up to 24”. A variety of belt styles, including solidsurface ThermoDrive and plastic link style belting, are compatible with the DynaClean conveyor. Drive flight options include standard, 75 degree and scoop flights and are selected based on product and desired throughput. The conveyors will accept product from a vibratory feeder or the company offers the option for stand-alone or attached hoppers for bulk product feeding. DynaClean conveyors are constructed of plastic and stainless steel materials that meet NSF, FDA, USDA and BISCC standards. The materials are corrosion resistant, non-toxic, non-absorbent and temperature resistant. The plastic side walls do not rot or retain harmful bacteria, odors or cleaning agents. The conveyors can be cleaned and sanitized with water, steam and/or detergents ranging from Sodium Hydroxide to Hydrochloric Acid. Dynamic Conveyor www.dynamicconveyor.com

www.foodmanufacturing.com

We sell your equipment, find that talented job applicant and bring your consulting service to the industry decision-maker. FOR INFORMATION, OR TO RESERVE SPACE, CALL: Tom Lynch, Advantage Business Media, at (973) 920-7782; or e-mail at: tom.lynch@advantagemedia.com.

EQUIPMENT AND MATERIAL SAFETY PLUGS PROTECT FROM ARC FLASH

OFF BUTTON Safely breaks load Rated up to 200A, 75hp

SAFETY SHUTTER Protects from live parts (on receptacle) meltric.com 800.433.7642

We sell your equipment, find that talented job applicant and bring your consulting service to the industry decision-maker.

HEAT EXCHANGERS Liquid Cooled

FOR

▼

▼ Air Cooled

GASES & LIQUIDS!

Talk Directly with Design Engineers! Blower Cooling

Vent Condensing

(952) 933-2559 info@xchanger.com

help you reach out to your audience... Advertise in the classifieds.

Terlotherm Scraped Surface Heat Exchanger Typical applications include Heating • Cooling Cooking • Pasteurization

(856) 241 9970 www.terlotherm.com

Call Tom Lynch Today! 973-920-7782

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 37

03/09/2015 13:47

IndustryINSIDER

Gluten-Free Trend Poses ‘Sticky’ Issue for Dough By Mark DiMaggio, Head of Food & Beverage, Linde LLC

nlike dough made from wheat flour, gluten-free dough does not easily form into a smooth ball because it lacks this important binder. That poses a challenge for dough and can also pose a challenge before final baking. For frozen or chilled dough products such as cookies, pizzas and breadsticks, the result after baking tends to be softer or chewier than people might expect. For soft cookies that might be acceptable. But crispy, thin-crust pizza is more difficult to achieve with sticky dough. During processing, dough that sticks to mixer blades and the sides of mixing/blending equipment can increase cycle times. Thorough mixing can become more difficult with gluten-free products, yet overmixing can impact dough quality and the texture of the finished baked product. At the same time, stickiness can contribute to yield losses per batch. Losses of just 2-3 percent can add up. Equally important, stickier dough can put a drag on downstream forming or processing operations — increasing process variability and contributing to unnecessary downtime, waste, and inefficiency. Chilling with ice at the mixer, especially bagged ice, is inherently prone to batch variation and increased labor, and that is a special challenge for bakeries scaling up. Tight temperature control before or during mixing can help alleviate these issues for faster cycle times, more repeatable operations, better dough handling characteristics, and more consistent quality of the finished product. With the proper know-how and engineering, processors can usually achieve such results cost-effectively with cryogenic chilling technology. A new, in-line cryogenic injection system can chill flour and other dry ingredients to within +/- 1 degree F of a setpoint as they travel from the silo to the mixer/blender. For dough processing, chilling dry ingredients as they are pneumatically conveyed is almost always preferred over batch chilling with ice at the mixer. New dry-ingredient chilling systems can provide upgrades over older chilling methods, or can be easily retrofitted to replace an older cryogenic system. Leading technology suppliers can customize dry ingredient chilling systems to meet plant-specific requirements. Prior to system installation, operating parameters for any new ingredient can be validated at a test laboratory. Dough and baking operations should always consider an engineered flour-chilling system when facing a major upshift in demand or planning an expansion, or whenever specifying a new silo or dry-ingredient pneumatic conveyor system.

Bottom-Up Chilling Approach Another alternative to any top-chilling method at the mixer is to inject liquid nitrogen or carbon dioxide (CO2) from the bottom. Cryogenic bottom-injection (BI) systems are designed to use the cryogen more efficiently than chilling with dry ice pellets or even CO2 snow from the top. The liquid cryogen is injected into food as it is mixing, and the cryogen captures additional BTUs in the phase change from liquid to gas, or liquid to solid to gas with CO2. Bottom injection systems have proven widely successful in the meat and poultry industry for chilling ground protein and fat during blending. If not properly chilled, fat can smear. Just as in the baking industry,

This month's more consistent temperature control in batch mixing can mean more consistent topic: forming and handling downstream — and BAKERY better finished product quality. Advanced BI chilling systems can be installed when purchasing a new mixer/ blender, or retrofitted to existing mixer/blenders. Design is key. Advanced systems are always customized to maximize processing efficiency, and these usually start with an in-plant assessment. In the baking industry, gluten flour doughs can also be sticky, and mixing operations can benefit from the same cryogenic chilling advantages. Mixing is the first and most important stage of dough processing. During ingredient mixing, both the development of the dough and the dough temperature are established. If either are not tightly controlled, product quality will suffer. Developing the gluten network through the dough requires adding energy and thorough mixing with the water and flour. The art is to develop the proper consistency so the dough will have excellent machinability as well as gas retention properties. When wheat flour is removed for a gluten-free recipe, other binders or combinations are added instead, though trying to match the overall performance of gluten can always pose a challenge.

Gluten-Free Health Trend Many consumers perceive “gluten-free” as healthy. So it is not surprising that gluten-free claims are extending to other food segments beyond bakeries and makers of dough products1. Picking up on the gluten-free trend, Smashburger started using gluten-free buns2, and Oscar Mayer now adds the claim to labels of qualifying products3. Gluten also finds its way into processed meat products in marinades and batter, as well as many binders, fillers and extenders. Hidden sources of gluten can include: spices and flavorings, caramel color, modified food starch, hydrolyzed vegetable protein, soy sauce, malt and maltodextrin. There are many gluten-free starches available. Starches bind moisture, provide heat and sheer stability, improve freeze/thaw stability and can enhance texture1. While Celiac disease only affects an estimated 1 in 100 people worldwide, 2.5 million Americans are undiagnosed and at risk for long-term health complications. The autoimmune disorder can occur in genetically predisposed people where ingestion of gluten leads to damage in the small intestine. Gluten-free diets are not just for those with Celiac disease, but also those with gluten sensitivity. According to a Mayo Clinic study, 1.8 million Americans have been diagnosed with Celiac disease, while another 1.6 million follow a gluten-free diet even though they haven't been diagnosed4. A survey by the NPD Group reports 11 percent of U.S. households include at least one person following a gluten-free diet, yet only about a quarter of those households identify Celiac disease or gluten sensitivity as the reason. 1 Jeff Gelski, “Report finds people view gluten-free items as healthy,” FoodBusinessNews.com, May 30, 2013. 2 Monica Watrous, “Smashburger goes gluten-free,” FoodBusinessNews.com. May 8, 2014. 3 Donna Berry, “Gluten-free meat,” FoodBusinessNews.com. Oct. 19, 2013. 4 “Gluten-free diet fad: Are celiac disease rates actually rising?” CBSNews.com. July 31, 2012.

September 2015

00_Food Manufacturing Sept2015_FINAL.indd 38

n 28/08/2015 20:02

IT’S YOUR

COMPANY LIFELINE WE HELP

KEEP IT MOVING When conveyor belts come to a halt, so does productivity. For more than a century, Flexco has been developing solutions to help keep them operating at peak production. We understand the challenges of keeping a conveyor line moving, across industries as diverse as agriculture, package handling and food processing. We’re committed to conveying innovations that help you maximize belt uptime, system productivity, and profitability. With a versatile range of conveyor belt fastener systems and endless splicing tools — like our new Aero® portable splice press, offering easy, on-site splicing — Flexco can help you achieve the optimum splice, with greater control, efficiency, and ease of operations.

Aero® Portable Splice Press

Partners in Productivity.

Learn more at ConveyingInnovation.com

00_Food Manufacturing Sept2015_FINAL.indd 39

28/08/2015 20:02

U.S. Tsubaki LAMBDA® Chain delivers the ultimate in power transmission technology offering long-term operation without additional lubrication. For packaging, food processing, or any lube-free application or where manual lubrication is unfavorable, LAMBDA® Chain is built for better, longer-lasting performance in maintenance-free operations. Available in drive or conveyor styles, LAMBDA® Chain keeps your operation running clean. And, you can find U.S. Tsubaki LAMBDA® Chain at your local Motion Industries location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running.

Scan this code with your smartphone for more information http://esp.to/wNMXwd

The brands you count on from the people you trust…that’s U.S. Tsubaki and Motion Industries.

Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations

00_Food Manufacturing Sept2015_FINAL.indd 40 MI21I11 – Tsubaki Food Manufacturing / SEPTEMBER.indd 1

28/08/2015 20:02 8/11/15 4:28 PM