JUNE 2020
NEW EQUIPMENT PAGE 24
T HE M A G A Z IN E F O R O P ER ATI O N S A N D M A NU FAC T U RIN G M A N A G EM EN T 43RD ANNUAL
CONSTRUCTION SURVEY
COVID-19 OVERSHADOWS PLANNING, ADDS TO SHORT LABOR SUPPLIES
Maintenance: An intelligent approach PAGE 56
PAGE 30
Pet Food: Premium product packaging PAGE 66
Robotics: Quality, safety drive adaptation PAGE 78
FOODENGINEERINGMAG.COM
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CONTENTS JUNE 2020
VOLUME #92
ISSUE #6
10 Calendar of Events
12 Editor’s Note
15 Manufacturing News Be ready for future virus outbreaks COVER STORY
21 Food Packaging Bioplastics in early stages
24 New Plant Products Controls and sensors
84
30
43RD ANNUAL CONSTRUCTION SURVEY COVID-19 overshadows project planning, decreasing already short labor supplies
Dry Processing Case packer helps Nature’s Path with environmental mission
90 Engineering R&D Heat exchangers get better with age
100 COVER PHOTO COURTESY OF GET T Y IMAGES
Nuts + Bolts
EATING MEAT (SUBSTITUTES) The global meat substitutes market will grow 16% CAGR from 2020 through 2024, driven by new product launches.
56>> 66>> 78>>
INTELLIGENT MAINTENANCE
SIMPLY THE BEST FOR PETS
ROBOT UPRISING
Today’s maintenance: From reactive to preventive to predictive to prescriptive
Packaging is king in the growing market for premium dog and cat food
How processors can use robots to enhance food quality and safety
Source: Technavio June 2020
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FOOD ENGINEERING Volume 92, Issue 6 (ISSN: Print 1522-2292 and Digital 1937-4429) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $152.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $187.00 USD (includes GST & postage); all other countries: $212.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2020, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146, Skokie, IL 60076.
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BEAUTIFULLY RESPONSIVE READING EXPERIENCES Enjoy our intuitive interface that allows you to read Food Engineering on your desktop as a digital replica or in our new Contents View, and on your phone as a scrollable series of articles.
SWITCH EASILY FROM THE TRADITIONAL VIEW TO THE CONTENTS VIEW
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INSTANT AUDIO While our digital edition has always supported audio in numerous ways, never before has audio been put front and center in the reading interface — think instant audio! With Audio Articles, you can open INSTANT your digital AUDIO edition on your phone and simply click on the speaker icon to the right of an article to listen to it.
PERSONALIZED CONTENT STREAM Using artificial intelligence, our digital edition can deliver a personalized stream of suggested PERSONALIZED content based CONTENT on your reading STREAM behavior and preferences. In the Menu Bar of the digital edition you can find your own personalized content channel!
PEST CONTROL DURING THE COVID-19 PANDEMIC How processors can adapt their strategies to fight new behaviors as pests look for different food sources during the outbreak > VIDEO
Watch more interviews on COVID-19 at www.foodengineeringmag.com/videos
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June 2020
GENTLE & SANITARY The PURMotion from PFI has revolutionized horizontal motion conveying in the potato processing industry. The servo drive allows for instant reversibility while maintaining the gentle gliding action required to convey fragile products. The PURMotion also features an open design along with IP69K components to allow for easy and effective sanitation. Whether your needs require a belt, vibratory, bucket or horizontal motion conveyor, WE KEEP IT MOVINGÂŽ
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CALENDAR J U LY
Cannabis Products Exchange
Hilton Denver City Center, Denver; Cannabis Products magazine, 844-644-7449 www.cpx20.com
Sept. 13-16
Food Automation & Manufacturing Conference & Expo
OCT.
Oct. 19-22
Food Safety Summit
Donald E. Stephens Doral Resort, Miami; Convention Center, Rosemont, Food Engineering Ill.; Food Safety Strategies; magazine; 844-644-7449 844-644-7449 www.foodautomationconference.com www.foodsafetysummit.com
June 2020 15: United Fresh LIVE! Virtual expo hall and educational sessions; United Fresh Produce Association; 202-303-3400 www.unitedfreshlive.org
July 2020 12-15: IFT20 Online talks and intensive courses; Institute of Food Technologists; 312-782-8424 www.iftevent.org
August 2020 24-25: Converters Expo
BNP Media Packaging Group; 610-436-4220, ext. 8514 www.globalpouchforum.com 14-16: New Products Conference Marriott Dallas Downtown, Prepared Foods magazine, 844-644-7449 www.newproductsconference.com 23-26: Natural Products Expo East Pennsylvania Convention Center, Philadelphia; New Hope Network/Informa Markets; 303-390-1776 www.expoeast.com
Lambeau Field Atrium; Green Bay, Wis.; BNP October 2020 Media Packaging Group; 610-436-4220, ext. 8514 15-16: The Beverage Forum Swissotel, Chicago; Beverage Industry magazine; www.convertersexpo.com 844-644-7449 www.beverageforum.com
September 2020 9-11: Global Pouch Forum Hyatt Regency O’Hare, Rosemont, Ill.;
10
FOOD ENGINEERING
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Event dates are changing because of COVID-19. This information was current at the time of publication.
June 2020
IMAGES COURTESY OF (FROM L TO R): CANNABIS PRODUCTS, FA&M, FOOD SAFE T Y SUMMIT
July 30-31
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FROM THE
CASEY LAUGHMAN
EDITOR
Editor-in-Chief laughmanc@bnpmedia.com
Embracing the future Digital transformation begins now for Food Engineering flexibility and the ability to do things we couldn’t do before. One of the things that I like about working for this magazine and its parent company is that it is very, very rare to hear “but that’s the way we’ve always done it.” From our corporate leadership all the way down, we’re encouraged to find new and better ways to do things, and if we find a new way f you’re reading this in print, then that truly is better, it’s quickly shared across you’re holding a small piece of history the entire company. in your hands. I would bet that also sounds familiar to a Beginning with our July issue, we will be a lot of you. But I bet it also sounds unfamiliar 100% digital publication. This plan has been to a lot of you, and you’re probably a little bit in the works for quite some time, and we’ve jealous right now. There’s nothing more frusknown there would be a day where we would trating than a good idea being unable to gain make this transition. Current events simply traction simply because someone is scared of accelerated the process. trying something new. The reasons for this change are many, and I In our case, we’re embracing the new. While could write pages on each of them. But they there won’t be a printed copy of Food Engiall ultimately boil down to this: The times are neering hitting your desk next month, there changing, and we need to change with them. will still be a digital edition arriving in your I’ll bet you’ve heard that one before. email. We’ll still be covering the industry We’ve all heard it, to the point that it’s bein much the same way, but with some new come a cliché. But clichés exist for a reason, tools at our disposal. and they’re usually rooted in a truth. In this It’s a strange time for a number of reasons, case, that truth is that much like the indusbut in this particular instance, it’s an exciting try we cover, the future of this magazine is time as well. I look forward to all of you joindigital. While the exact reasons and execuing us on this new journey. tion are different when we’re talking about magazines versus food production, the basic concepts are the same: better data, more Beginning with the July 2020 issue, Food Engineering will move to a digital format.
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FOOD ENGINEERING
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June 2020
PHOTO COURTESY OF GET T Y IMAGES
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PRODUCE CLEANING SOLUTIONS ON DEMAND IN YOUR PLANT WITH THE KLARION™ SYSTEM Shortages and longer lead times for cleaning and sanitizing products pose serious risks to production. Producing cleaning solutions on demand in your plant reduces dependency on chemical suppliers and mitigates risk. The Klarion on-site generation system produces cleaners and sanitizers that are just as effective as traditional chemicals and can be used throughout your plant.
CLEAN EVERYWHERE Klarion solutions can be widely used throughout your plant. Solutions can be fed into CIP systems and used in pressure washers, mobile carts, buckets, handheld sprayers, spray guns and spray bottles. Clean and disinfect when and where needed – equipment, tanks, totes, work and break areas, bathrooms, floors and more.*
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Learn more about the benefits of Klarion on-site generation at spray.com/klarion or call 1.800.95.SPRAY. *See website for Klarion sanitizer/disinfectant efficacy details and usage instructions.
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FOR THE MOST UP-TO-DATE NEWS AND INFORMATION
Visit us at FoodEngineeringMag.com
Be ready for future virus outbreaks
CONTINENTAL MILLS, maker of baking and breakfast brands, purchased a 175,000-sq.-ft. facility in Effingham, Ill., which will be renovated and in service in 2021. JUSTFOODFORDOGS opened a 21,000-sq.-ft. master kitchen in New Castle, Del., which will process 15 tons of fresh pet food per day and provide 75 jobs.
IMAGE COURTESY OF GET T Y IMAGES
The Ireland-based KERRY GROUP is investing $125 million in a 360,000-sq.-ft facility in Rome, Ga., to produce taste and nutrition solutions for poultry, seafood and alternative protein products. It will open in 2021. MCKEE FOODS (Little Debbie snacks) plans a 15-year investment of more than $500 million to expand its Collegedale, Tenn., operations. In the first five years, $110 million has been set aside to double the size of its Apison facility with a new production line.
June 2020
C
The pandemic could have a OVID-19 will continue to make an impact on the food variety of impacts on plant construction projects, possibly industry and its supply chains. pushing processors to FE spoke with a few experts from the A&E/C community to allocate space to produce get a wide-angle view of some of flexible product sizes, handle surging demand or space the key issues. out workers. “The COVID-19 pandemic has the potential to drive significant change to the food and beverage supply chain,� says Keith Perkey, vice president, Haskell Food & Beverage Division. Previously processors were reluctant to have extra capacity in warehouses or on production lines; however, given the learning that will come from the supply chain disruptions caused by COVID-19, that model may change and drive additional capacity to be constructed. There is also a significant likelihood that a contagious virus will add complexity to how manufacturing systems are laid out to provide additional social distancing and monitoring if necessary. The surge and shift in customer and consumer demand from the foodservice channel to retail, driven by increased
FOOD ENGINEERING
foodengineeringmag.com
15
MANUFACTURING NEWS at-home usage due to COVID-19 sheltering-in-place precautions, will result in some consumer packaged goods manufacturers seeing
a corresponding increase in volume, revenue and profit, says David Ziskind, director of engineering, NextGen Ag, Black & Veatch. Additionally,
PREVENT CONTAMINATION Sonic’s HEPA Filter For any plant that has exposed food product, it’s critical to have a filtered drying system that keeps the food safe from contamination during blow off. Sonic Air’s in-line HEPA filter is perfect for your Sonic Air Knife system.
• With the HEPA filter at 0.3 micron, you can be sure your raw product will be safe on the processing line.
• Sonic’s in-line HEPA filter has an airflow rate up to 1000
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For a complete catalog contact Jim Schmidt today:
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920.921.4760 ext 175
Marchant Schmidt is a manufacturer, re-builder, and distributor for products serving the food, dairy and beverage industries worldwide.
SERVING THE FOOD INDUSTRY SINCE 1963
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many food manufacturers may want or need to address their facilities and operations to be even more prepared in the event a similar situation would occur again. This could result in manufacturers upgrading or renovating facilities to better address flexibility in producing a variety of product sizes, etc., as well as employee safety best practices. THE COVID-19 OUTBREAK MAY CAUSE SOME PROCESSORS TO BUILD IN EXTRA CAPACITY TO HANDLE SURGES.
Funding has become more available. “With ‘cheap money,’ companies can build a facility for their projected future needs with either traditional bank financing or asking for extended payment terms from vendors,” says Ziskind. However, often much of this investment is driven by the need to update older facilities to meet Food Safety Modernization Act compliance standards, says Brian Commerford, Food & Consumer Products Group, Burns & McDonnell. “We are also seeing investment increases in new processes and production lines as the demand grows for innovative prodJune 2020
MANUFACTURING NEWS ucts and packaging. On the other side of the investment spectrum, greenfield plant spending is primarily taking place in the dairy and meat processing sectors.� What about renovating a brownfield site? Saving a few dollars by purchasing an existing or brownfield facility may not make sense, especially if a manufacturer might inherit a design that is not ideal for its needs, or a facility that contains existing pathogen loads, says Ziskind. Combined with state and local incentives, greenfield facilities for large manufacturers tend to make sense. Automation can help solve some of these problems and is gaining traction, particularly in packaging, warehousing and distribution operations, says Commerford. Thanks to rapidly advancing artificial intelligence technologies, automation provides repeatability and removes human error. The use of automated storage and retrieval systems (ASRS) is increasing in popularity as processors look to reduce labor costs across their supply chain networks. ASRS can be used for a wide variety of food product types in both the ambient and refrigerated spaces. As demand for fresh foods increases, distribution and warehousing June 2020
facilities need to be in closer proximity to consumer markets, where real estate prices play a major factor in total cost of ownership.
For more on the state plant construction, see FE’s Annual Plant Construction Survey on Page 30.
ENGINEERED BLOWERS & AIR KNIFE SOLUTIONS Sonic Air Knife Systems lead the industry with exceptional engineering, quality and performance, providing you with a sufficient payback on your investment. These energy efficient blower-based systems are ideal for many types of applications in the food, dairy and beverage industries with just a few examples listed here.
Packaging Cans Bottles Jars Pouches Films
Food Products Cheese Fruits Vegetables Bakery Frozen Products
Carriers Belts Crates Trays Racks
Dry Surfaces Labeling & Coding Cartoning Film Wrapping Sleeving Freezing
For a complete catalog contact Jim Schmidt today: jpschmidt@marchantschmidt.com
920.921.4760 ext 175
Marchant Schmidt is a manufacturer, re-builder, and distributor for products serving the food, dairy and beverage industries worldwide.
SERVING THE FOOD INDUSTRY SINCE 1963
FOOD ENGINEERING
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MANUFACTURING NEWS
//
REGUL ATORY WATCH
FDA issues guidance on FSMA thirdparty certification amid COVID-19
Regulatory Watch
SAME COMPANY. NEW LOOK.
Tunnel Style Metal Detectors are Essential for Product Purity The meTRON™ 07 CI with conveyor provides superior metal detection with the widest range of customization options available. • Stainless Steel for washdown environments. • Enjoy the ability to select from diverse reject options, including a belt stop, belt stop and reverse, air blast, 90° pneumatic pusher, 45° sweeper arm, retracting nose pulley, decline nose pulley, or a flap gate installed at the end of the conveyor. • To best transport your materials, we offer modular belting or fabric belting to outfit the conveyor with. • Controlling the system is simple, and our give you the option to input variable speed using an encoder. • In order to accommodate your work environment, the equipment has adjustable height leveling pads and casters available. • Now Available with Optional Triple Frequency Controls - Learn a packaged food product in three different conditions, and select the one with that yields the greatest sensitivity. • Automatic Protocol Export - Provides an automatic backup of all metal detector events. • Any meTRON™ unit can be custom built to your exact specifications, and will arrive at your facility ready for installation.
800.835.2526 / Sales.Newton@BuntingMagnetics.com Visit BUNTINGMAGNETICS.COM
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The guidance addresses the challenges with conducting onsite monitoring activities during the COVID-19 public health emergency by providing temporary flexibility so that recognized accreditation bodies (ABs) can maintain the accreditations of certification bodies (CBs), and so that already-issued certifications need not lapse, where certain safeguards are in place. Recognized ABs are required to monitor the CBs they accredit through a comprehensive assessment of their performance. While certain monitoring requirements can be done remotely, FDA recognizes that it may be temporarily impractical to conduct on-site monitoring activities; therefore, in certain circumstances, the agency does not intend to enforce those requirements. For certificates set to expire, the FDA understands that current travel restrictions and advisories related to COVID-19 may hinder the ability of accredited CBs to conduct the on-site regulatory audits needed to recertify the foreign entity. An accredited CB that has issued a certificate with an upcoming expiration date can contact FDA at FDAthirdparty program@fda.hhs.gov to discuss the term. June 2020
INDUSTRY NEWS AVEVA has acquired MESENTER, a production accounting software provider, to complete AVEVA’s Value Chain Optimization solution. AVEVA also announced a new partnership with AXONIFY to offer AI-powered micro-learning solutions for industrial operations staffs. SAFETYCHAIN announced a strategic agreement with EUROFINS FOOD ASSURANCE to deliver a remote certification solution to customers in North America, allowing food suppliers to cope with COVID-19 travel and social distancing restrictions.
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including U.S. Water Services Inc., Kurita America Inc., Fremont Industries and Global Water Services Holding Company Inc. The
MANUFACTURING NEWS newly combined company will be known as KURITA AMERICA INC. and will be headquartered in St. Michael, Minn.
What are you watching? Expand your knowledge with videos from
BOLTHOUSE FARMS entered into an agreement to acquire Arizona-based ROUSSEAU FARMING CO.’S carrot operations. STANDEX REFRIGERATED SOLUTIONS GROUP reached a definitive agreement to sell its MASTER-BILT and NOR-LAKE refrigeration businesses to TEN OAKS GROUP, a firm focused on corporate divestitures. KURITA WATER INDUSTRIES completed the merger of its consolidated subsidiaries in the U.S., June 2020
foodengineeringmag.com/videos FOOD ENGINEERING
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MANUFACTURING NEWS
//
PEOPLE NEWS
The CONSUMER GOODS FORUM said PETER FREEDMAN will step down as managing director, and WAI-CHAN CHAN, senior partner and co-leader of the retail and consumer goods practice at Oliver Wyman, will assume the role. He has more than 25 years of retail and CPG experience. ERIEZ appointed LUKAS GUENTHARDT president and CEO. Guenthardt fills this role following TIMOTHY SHUTTLEWORTH, who retired after serving as president and CEO since 2004.
ALLIED ELECTRONICS & AUTOMATION named MANISHA KADOCHE as CFO, KATIE CARTWRIGHT as VP of human resources and JESSIE DEARIEN as VP of marketing.
Interstate Warehousing • 5th largest PRW in U.S.A.
Tippmann Construction • Design/build construction
• 115,000,000 cubic feet of cold storage space • SQF certified facilities • Customized distribution solutions • Retail and Foodservice consolidation programs • Comprehensive management development & training program
of multi-temperature warehouse and production facilities • New builds, expansions and renovations • More efficient blast freezing with QFR Zone® technology • Master site planning • Members of U.S. Green Building Council • Owner/operator experience & knowledge
TOMPKINS INTERNATIONAL appointed DENNY MCKNIGHT at its new CEO after former CEO and founder JIM TOMPKINS stepped down after 45 years in that job. Tompkins will remain as chairman. NACS appointed BRIAN KIMMEL as its executive vice president, COO and CFO. NEOGEN reports that JAMES HERBERT resigned as chairman and has been succeeded by JIM BOREL.
9009 Coldwater Road • Fort Wayne, IN 46825 • (260) 490-3000 • www.tippmanngroup.com
FOOD
ROSE SHILLING MANAGING EDITOR
PACKAGING
Bioplastics ripe for innovation Report: Compostable, biodegradable packaging still in early stages of adoption
PHOTO COURTESY OF GET T Y IMAGES
B
ioplastic packaging remains in the early development stage with no dominant companies, a new analysis finds. About 40% of inventions are held by organizations with just a single invention, a sign of how little development has occurred so far, according to a report by Clarivate Analytics, a firm that provides insights to accelerate innovation. Less than a tenth of organizations have 10 or more inventions in the field. The “relatively small and nascent market” lags public sentiment for sustainable plastics alternatives, Clarivate says in “From the Plastics Present to a Sustainable Future.”
June 2020
Patent volume in bioplastics The small market for bioplastics packaging for food, beverage patents lags the public’s desire for and cosmetics sectors increased sustainable plastics alternatives. about 60% to 70% from 2012 to 2017, simply keeping pace with overall patent volumes that similarly grew 70% over the same period, according to the Derwent World Patents Index. Derwent is one of Clarivate’s companies that help build brands that innovate. Bioplastics, around for more than 100 years, “developed in the shadow of the plastics industry,” Clarivate notes. Production today is just a fraction compared to the more than 359 million tons of plastic produced annually. Biodegradable or recyclable plastics are not yet commercially attractive options, Clarivate says. Until the economics of production improve, adoption will continue to be slow. “Bioplastics may not be the green savior they are touted to be by some, but as the world seeks credible alternatives to plastics, we can expect more innovation and the continued growth of bioplastics,” the report says. FOR MORE INFORMATION, VISIT WWW.CLARIVATE.COM FOOD ENGINEERING
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21
FOOD PACKAGING
Paper with recyclable barrier hits on a big challenge for food containers ortec Corp. has created an alternative coated paper, which hasn’t been easily recyclable through normal channels. EcoShield Recyclable Barrier Paper and Linerboard is coated with a water-based barrier that can be recycled and repulped to be made into other paper products. The coating resists moisture, grease and oil. When tested according to ASTM E-96, EcoShield shows a water vapor transmission rate (WVTR) comparable to polycoated pa-
P H O T O S C O U R T E S Y O F C O R T E C C O R P.
C
Coated paper is difficult to repulp. Cortec Corp. has come up with a water-based barrier that’s recyclable.
per and far superior to waxed paper, the St. Paul, Minn.-based company says.
FOOD PACKAGING EcoShield barrier paper can be repulped and turned into other paper products.
• §176.180-Components of paper and paperboard in contact with dry food “This represents good resource stewardship while still achieving critical packaging qualities,” Cortec’s announcement says. “Users of EcoShield Recyclable Barrier Paper and Linerboard thus have the opportunity to contribute to a circular economy while still getting the benefits of moisture barrier packaging.” EcoShield comes in a variety of custom sizes, from precut sheets for end users to jumbo rolls for packaging suppliers and paper converters.
The paper is made from components formulated in compliance with FDA Code of Federal Regulations Title 21: • §176.170-Components of paper and paperboard in contact with FOR MORE INFORMATION, VISIT WWW.CORTECPACKAGING.COM aqueous and fatty foods
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June 2020
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FOOD ENGINEERING
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NEW PLANT
PRODUCTS
FOCUS ON controls & sensors
SOLID STATE RELAYS Senata Technologies • www.sensata.com The LN solid state relays (SSRs), from Sensata’s Crydom brand, conform to IEC 60947-4-3 Environment B and CISPR 11 standards for low voltage domestic, commercial and light industrial locations/installations and are compliant with C-UL-US and TUV certifications. The LN Series of panel mounted solid state relays offer back-to-back SCR switching up to 75 amps at 528 VAC.
ULTRASONIC FLOWMETER KROHNE Inc. • https://krohne.com OPTISONIC 6300 V2 ultrasonic flowmeter allows users to measure flow anywhere necessary, all while processes continue. With a viscosity
24
FOOD ENGINEERING
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range of up to 200 cSt, there is no need for re-greasing due to solid coupling material. Unit has a signal converter for enhanced application range, Namur NE107 diagnostics and integrated thermal energy calculation. Process temperature range is -40 to 392°F (-40 to 200°C). Unit is designed to deliver accurate sensor alignment using rail mounted transducers, and minimized uncertainty through installation wizard and optimization routine.
INDUSTRIAL MICRODRIVE Yaskawa America Inc. • www.yaskawa.com GA500 is designed to meet RoHS2, providing a sustainable and an environmentally friendly drive. Its TUV safety rating allows users to meet the most stringent safety ratings for their machine and provides a long mission time for the life of their equipment. Drive is rated up to 40 hp and can be applied to 240 VAC single-phase, 240 VAC threephase or 480 VAC three-phase incoming power. It can operate a range of motors, including induction, permanent magnet (SPM and IPM) and synchronous reluctance (SynRM).
June 2020
Visit us at booth #300
SSV Sanitary Drum Motors Reduce Washdown Time. Minimize Downtime. Reduce washdown time by up to 50% with the all-316 stainless steel continuous profile SSV drum motor. The belt profile is machined directly onto the drum to drive modular and thermoplastic conveyor belts without the use of sprockets. Designed for food processing belt conveyors where sanitation is paramount. Vist vandergraaf.com/fe to learn more.
• NO EXTERNAL DRIVE PARTS • NO PLASTIC SPROCKETS • NO MAINTENANCE
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Made in USA
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SSV Sanitary Drum Motors Reduce Washdown Time. Minimize Downtime.
The most sanitary drive for your belt conveyor. The continuous profile SSV drum motor with the belt profile machined directly onto the drum eliminates bacterial harborage areas and foreign material contamination, reducing washdown time by up to 50%. Vist vandergraaf.com/fe to learn more.
• ELIMINATE FMC • ELIMINATE PRODUCT BUILD-UP • ELIMINATE BACTERIAL HARBORAGE
(888) 326-1476 • info@vandergraaf.com
Made in USA
NEW PLANT PRODUCTS
CONTROL SYSTEM Volkmann Inc. • www.volkmannUSA.com The ET Special Control System is designed to cover a range of configurations in its vacuum conveyor systems. Equipped with a 4" high-definition touch display, the system works with maximum level sensors on product collection, the conveyor and the product delivery site.
VACUUM TUMBLER Hollymatic • www.hollymatic.com HVT-30 vacuum tumbler is designed to increase yield, tenderize product, reduce cook time, and evenly distribute flavor throughout product whether it is meat, fish or poultry. Features include a built-in vacuum pump, programmable timer (10 6-min. increments), 25 lb. maximum working capacity, variable speed from 1 to 18 rpm, and removable stainless tank.
June 2020
TRAY PACKAGING SOMIC America Inc. • www.somic.us The 424 series is designed for medium to high outputs. The covered tray machine can be customized for a confectionery manufacturer and processes up to 380 products per minute. The products are packaged either fl at or upright—depending on the format, in a single or double row—into two-part cardboard packaging.
BULK BAG DISCHARGING SYSTEM Material Transfer • www.materialtransfer.com Patented system designed for discharging ingredients into existing process features an electric chain hoist and Spider-Lift bag lifting frame equipped with a custom debris shield to prevent contaminants from entering the process. It is FDA and USDA approved for areas of direct and indirect dry food contact.
FOOD ENGINEERING
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NEW PLANT PRODUCTS
BATCH WEIGHING Coperion K-Tron • www.coperion.com A range of batch weighing options for food ingredients into mixers, hoppers or packaging lines. For scale hoppers, the system controller diverts conveyed material to the scale hopper, which is suspended on high accuracy load cells. Once the batch weight has been reached, the fill valve closes and redirects material either to the next scale weigh hopper or back to either the original material source point or to a dust collector. Conversely, when batch weighing with screw feeders by either GIW or LIW methods, a two-phase batch cycle is used. During the first phase, 90% of the batch weight is delivered. In the second phase, the last 10% is fed in a slower “dribble” mode to ensure an accurate batch weight equal to +/- 0.1% of desired set point.
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FOOD ENGINEERING
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AUTOMATED TOTE MANAGEMENT SYSTEM Harpak-ULMA • wwww.harpak-ulma.com Tote systems employ reusable containers made of plastic or cardboard to transfer products, accommodating a range of products and primary packaging types. Reusable plastic totes are easy to clean, hygienic, resist water and chemicals, and are consistently sized. The system uses a closed-loop process to drive cost savings.
STANDARD DUTY LIFTING BEAM Harrington Hoists Inc. • www.harringtonhoists.com HSDLB Standard Duty Lifting Beam is designed for low headroom applications and available from ½ through 40-ton capacities with outside spreads from 3 to 30 ft. Additional sizes and capacities are available. Three standard lift points for load adjustment are included. Supplied with a pair of heavy-duty swivel hooks, additional lift points and hardware are available as options.
June 2020
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43 CONSTRUCTION rd
annual
SURVEY
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June 2019
COVID-19 overshadows project planning and construction while decreasing already short labor supplies as healthy people are also quarantined BY WAYNE LABS, SENIOR TECHNICAL EDITOR
L
ike Monty Python’s famous “Nobody expects the Spanish Inquisition,” certainly no one expected—at least way back on New Year’s Day 2020—the coronavirus (aka COVID-19) would come out of seemingly nowhere and close down so much of the world’s economy, while inflicting such a great global toll on human lives. But, COVID-19 has tested our industry and its supply chains, and we’re learning about the industry’s resiliency in the process. A few days after New Year’s, I prepared the 2020 survey questions for this article, thinking we had a pretty good economy during the last year. And we did. There were already supply chain changes on the way, spurred by the market for home deliveries of high-end meal kits and grocery store deliveries (e.g., Giant/ Peapod), and with Amazon’s purchase of Whole Foods, there was a trail to be blazed in home deliveries. Little did we know, however, just how well this new home delivery market concept and the food supply chain in general would be tested as we stayed at home in quarantine. COVID-19 AND ITS IMPACT ON CONSTRUCTION While this year’s number of 609 projects for calendar year 2019 in June 2020
TOP 10
A & E /C H O T TRENDS
01
Increasing production to meet demand
FE’s Plant Construction Survey (new and expansions/renovations) follows a small, incremental downward trend over the last four years, it’s difficult to know how much COVID-19 has affected the reporting this year. We’ll look into the numbers in more detail a little later after we explore some of the trends—especially coronavirus—related by the A&E/Cs for this article. Keep in mind that many of the responses from A&E/Cs in this article reflect business before COVID-19 took hold on our economy. Depending upon where your business is located, COVID-19 has had different impacts. “Due to COVID-19, some project sites are being closed due to government mandates, and other projects are being delayed,” says Don Oberlies, VP/market leader, Alberici Constructors. “Equipment deliveries from other impacted countries are also adding to the delays.” In Pennsylvania, where I live, what’s considered an essential business and what’s not in the COVID-19 environment isn’t always so clear, but the outbreak has hurt construction. “In Pennsylvania, the deeming of construction as non-life essential has hurt construction projects across the board,” says Mark Galbraith, co-owner of Galbraith Pre-Design Inc. “Other
02 Food safety: FSMA regulations/GFSI (design, layout, etc.)
03 Capital availability
04 Automation: process control, robotics, packaging, etc.
05 Overall cost/controlling costs
06 Fast project deployment
07 Flexibility in plant design to accommodate flexible manufacturing
08 Ability to easily manage subcontractors
09 Old plant vs. build new—often easier to build new than upgrade
10 Workplace safety
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43RD ANNUAL PLANT CONSTRUCTION SURVEY
01
Food safety: FSMA regulations/GFSI (design, layout, etc.)
02 Capital availability
03 04 Flexibility in plant design to accommodate flexible manufacturing
05 Increasing production to meet demand
06 Workforce availability (line workers)
07 Overall cost/controlling costs
08 Automation: process control, robotics, packaging, etc.
09 Ability to change design when building
Workplace safety
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June 2020
CHARTS FOOD ENGINEERING
Copyright Food Engineering 2020
Fast project deployment
10
Ratio of expansions/renovations to new projects
T R E N D S A & E /C F I R M S S AY A R E OF MOST CONCERN TO FOOD PROCESSORS
than mainteRatio of expansions/renovations to new projects 2010-2019 nance (in order to 800 3.0 keep facilities in 2.81 694 700 679 compliance with 635 629 609 600 640 600 food safety regu555 2.42 2.5 500 490 lations), projects 453 2.48 2.38 2.21 are shut down. 400 2.03 This includes one 300 2.14 2.0 of our sizeable 200 projects, which 1.89 1.82 100 halting progress 1.75 may affect the 0 1.5 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 producer’s ability Ratio of Expansions/Renovations to New projects to meet demand Total annual projects or merge into new products In this graph, the gray bars represent the and markets once the nationwide total number of projects each year from quarantine is lifted. It is also affecting the entire supply chain. In Pennsylvania, 2010 to 2019. The red trace shows the ratio of expansions/renovations to new dairy farms have been forced to dump projects. From 2012 to 2017, the ratio of raw milk down the drains.” For Epstein, Darrin McCormies, se- expansions and/or renovations to new nior VP, director of industrial services, projects had increased, indicating in 2017 that about three out of four projects reports that since the emergence reported were expansions and/or of the COVID-19 pandemic, projects renovations. In 2018, the trend had rein the food industry have continued versed, indicating a trend towards a greater with no slowdown in expected compercentage of new construction projects. pletion dates. He also says his firm has taken on cannabis projects as there have been several new comFor example, Forrest McNabb, execpanies anticipating the widespread utive vice president of Big-D Construcgrowth of the cannabis industry. tion, reports that while the availAt the time of writing this article, ability of construction materials has due to COVID-19, we’ve seen the clo- remained surprisingly stable over the sure of four Smithfield facilities in the last year, the labor situation remains U.S., several Tyson operations and a stressed due to a very low unemploycouple of JBS plants, putting a crimp ment rate in the construction business. on the protein supply chain. The And he adds, “While dealing with that, supply chain for construction matewe then have COVID-19 arrive and rials, however, has not been quite as there are some immediate impacts in affected, but finding labor remains a managing projects to assure the safety perennial problem. and health of the labor force.” Total number of projects
TOP 10
Proven leadership in food and beverage plant design Reliable | Knowledgeable | Trusted 513.241.1230 | Info@hixson-inc.com | www.hixson-inc.com 659 Van Meter Street, Cincinnati, OH 45202
43RD ANNUAL PLANT CONSTRUCTION SURVEY McNabb, an industry veteran, describes something all too familiar. “It is the first time in my career that we are having to do weekto-week strategic planning based on the unknowns in dealing with COVID-19 versus our actual short-term and long-term strategic planning. We are optimistic ‘this too shall pass,’ but it is all hands on deck with weekly meetings, making sure we are very proactive in maintaining best practices with our people and projects to stay out of harm’s way.” “The pre-COVID-19 economy, as we all know, was strong and vibrant, marked by record low unemployment and widespread resource constraints across the trades, project and construction management and engineering professionals,” says Gregory Franzen, Faithful+Gould agrifood subsector lead. “Yet to be seen is the resilience of our industry to adapt to the new complexities presented to us with COVID-19.” The future is a little nebulous for some processors. “Construction projects were going strong, and the outlook for the year looked great before COVID-19 became a pandemic,” says Matt Hartenstein, P.E., mechanical engineering manager, Mechanical Process Group, Shambaugh & Son. “Now the outlook is unclear as companies are slowing down and/or putting projects on hold.” While the coronavirus may not have adversely affected the construction goods supply chain, it has had an impact on planning and lead times as Franzen summarizes risks and challenges: From 2016-2017, the number of new projects had become a smaller piece of the total number of projects while processors concentrated more on renovations (Ren.) and expansions (Exp.) to meet regulatory, time-to-market and production demands. However, beginning in 2018—and even larger in 2019—the trend had reversed in favor of new projects assuming a greater percentage of total projects.
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• Adapting to different safe work practices on projects in a fully operational plant environment. • Planning for lead time impacts to process and other equipment manufactured overseas. • Learning how best to engage on-site differently, respecting social distancing requirements, meaning the way we meet and engage on-site about projects may change. While there are apt to be delays in project planning, spending and construction scheduling, some A&E/C folks are, however, thinking positively with a good end in sight. Says Lloyd Snyder, Woodard & Curran senior VP, “Pre-virus, the spending was increasing. I think this pause in spending will end with a surge not seen since the end of WWII. Manufacturing will have a renaissance.” “Despite being inundated with concerning news on a daily basis, both from a global health and a global economic standpoint, food and
2016 through 2019 projects (percent of total) 26.2%
28.7% Ren./ Exp.
New 71.3%
2016 Projects (total = 679)
Ren./ Exp.
29.3% New 70.7%
2018 Projects (total = 629)
Ren./ Exp.
New 73.8%
2017 Projects (total = 640)
Ren./ Exp.
33% New 67%
2019 Projects (total = 609) Copyright Food Engineering 2020
June 2020
New facilities (green) and expansions/ renovations (brown) are shown for years 2010-2019. Total projects = New + Exp./Ren.
Plant construction projects from 2010 to 2019 800
694
700
600
600
635
679
640
629
609
wastewater treatment projects and new process plant construction as 500 453 some older facilities are beyond 400 upgrading. More on this later. 345 312 382 358 415 473 484 472 445 408 300 While the 2019 total number of reportable food and beverage plant 200 projects (expansions, renovations, 100 new or combination thereof) totaled 145 141 218 197 220 221 195 168 184 201 609, the number was down the 2018 0 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 total of 629, representing a 3.2% New (greenfield projects) Brownfield: Expansion, renovation or both drop. However, 2019’s number of new Copyright Food Engineering 2020 projects (201) showed an increase of beverage processors, for the most part, seem 9.2% over 2018’s number of 184. In to be galvanizing around their role as essential addition, though the number of recorded 2019 businesses and vital components of maintainDC/warehouse-only projects (100) was smaller ing the safety and survival of the populace,” than the previous year’s 123 projects (a 10-year says Mark DiGino, director of business develop- high), DCs and warehouses still accounted for ment, E.A. Bonelli + Associates. “It hasn’t been 16.4% of total projects, whether renovations, exeasy to adapt to rapidly changing conditions, pansions or new projects. Compared to 2018, the but we are picking up on more optimism than 2019 number was down by 18.7%, but still 53.4% pessimism … Site visits for design and contract- higher than the 10-year average of 65.2 units. ing personnel have obviously been halted, but Reportable food and beverage projects are we’ve found that even that has done little to those valued at over $1 million. They have been stop our clients from proceeding with plans made public by the processor, a government that had been in motion prior to any ‘shelter in entity (including local or state economic develplace’ or ‘safer at home’ orders.” opment groups), or the A&E/C firms responsible for them. The survey (though the table WHAT THE NUMBERS SAY ABOUT 2019 lists “Completion Date” at the header) includes The numbers reported this year by A&E/Cs projects begun, announced by any entity or reveal a couple of interesting trends in calencompleted in 2019. If dates listed are beyond dar year 2019. First, the state of new projects 2019, they reflect the projected completion remains healthy, especially considering new date for a project either announced in 2019 or warehouse and distribution center (DC) projunderway in 2019. Projects that appeared in ects to support our growing, online shopping last year’s table with a 2019 date were carried habits—given a shot in the arm by the coroover—unless there was an obvious duplicate. navirus keeping us home and not shopping in Keep in mind, some projects can be announced, person or eating at restaurants. In addition, then dropped at the last minute for any number several A&E/Cs reported an increase in pre/ of reasons, e.g., legal problems, lack of expected 555
Number of projects
490
June 2020
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43RD ANNUAL PLANT CONSTRUCTION SURVEY funding, site issues, changing needs, politics, etc. In the table, “D/W” refers to distribution/warehouse, and “DC” refers to distribution center; “Exp.” refers to expansion and “Ren.” is for renovations, and some projects include both. A more detailed look at the numbers shows pet food projects numbered 23 out of 609, and alcoholic beverage projects numbered 41, down 25.5% from 55 projects in 2018. The total number of projects at 609 represents a 1.8% increase over the 10-year average of 598.4 projects. New projects for 2019 (201) showed a 6.3% increase over the 10-year average of 189, while expansions and renovations (408) showed a 0.3% decline over the 10-year average of 409.4 projects. Also interesting is that this year’s ratio of expansions/renovations to new facilities has again dropped since 2017, when the ratio was 2.8:1, the highest in the last 10 years. That ratio declined to 2.03:1 in 2019, indicating an increasing number of new projects. LABOR CREATES COMPOUND ISSUES Even before the emergence of COVID-19, there was an industrywide labor shortage. “Construction employment opportunities are at an all-time high, but the number of new entrants into the workforce continues to steadily decline each year,” says Heath Catt, Construction/Design-Build Group, Burns & McDonnell. “Widespread labor shortages are not limited solely to field construction. This trend is also taking its toll on suppliers and fabricators, affecting shop production levels and driving up the prices of manufactured equipment.”
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THE FOLLOWING COMPANIES AND INDIVIDUALS PARTICIPATED IN THE FOOD ENGINEERING SURVEY: A M King www.amkinggroup.com
Food Plant Engineering www.foodplantengineering.com
ADF Engineering, Inc. www.adfengineering.com
Galbraith Pre-Design Inc. www.gp-inc.com
Alberici Constructors www.alberici.com
Gleeson Constructors & Engineers LLC www.gleesonllc.com
ARCO National Construction www.arconational.com
Gray Construction www.gray.com
Big-D Construction www.big-d.com
Hixson Architecture & Engineering www.hixson-inc.com
Black & Veatch www.bv.com
Mead & Hunt www.meadhunt.com
Burns & McDonnell www.burnsmcd.com
Shambaugh & Son L.P. www.shambaugh.com
CMC Design-Build Inc. www.cmcdesign-build.com
SSOE Group www.ssoe.com
CRB www.crbusa.com
Stellar www.stellar.net
Dennis Group www.dennisgroup.com
The Austin Company www.theaustin.com
E.A. Bonelli + Associates www.eabonelli.com
The Haskell Company www.haskell.com
Epstein www.epsteinglobal.com
Tom Wiersma, independent consultant 616-293-3411
ESI Group USA www.esigroupusa.com
Tippmann Group www.tippmanngroup.com
Faithful+Gould www.fgould.com
Woodard & Curran www.woodardcurran.com June 2020
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43RD ANNUAL PLANT CONSTRUCTION SURVEY Distribution center/warehouse and alcoholic beverage projects 2010 through 2019
150
Distribution center/warehouse (all food/bev. types) 123 Alcoholic beverage projects* 100 90
90
82
85
78 70
60
30
53 41
Data not recorded*
50
Data not recorded*
Total number of projects
120
44 42
42 31
47
63
55 41
For the past eight years, FE has also been tracking alcoholic beverage producing or warehousing facilities. In 2019, the number of distribution center/warehouse projects for all food and beverage types dropped 18.7% from the peak in 2018. The DC/Whse. category includes both new facilities and expansions, but only projects dedicated to distribution and warehousing (no processing).
Sadly, this labor shortage can have unintended consequencY2010 Y2011 Y2012 Y2013 Y2014 Y2015 Y2016 Y2017 Y2018 Y2019 Copyright Food Engineering 2020 es on smaller projects. David Ziskind, Black & Veatch direcLike suppliers and fabricators who’ve automat- tor of engineering, NextGen Ag, says, “In the ed to be more productive, construction is begin- construction sector, with record employment, ning to require more technical skills than needed finding qualified/skilled labor is a challenge for to run a backhoe. The typical construction contractors, and many contractors are adjustworker is now required to be smarter and more ing their bids to favor larger projects—in some technologically savvy than ever before, says Bri- cases making it difficult to accurately estimate an King, A M King owner and president. “As more and even source smaller projects.” automation, robotics and software applications impact how structures are built, the individuals SCHEDULING ISSUES BEFORE COVID-19 operating this equipment and technology must There seems to be an adequate supply of also be better trained and more proficient. The materials and labor for projects, but you can’t future construction worker will spend more time forget about labor, says Mark Redmond, PE, operating a machine than operating a tool.” president of Food Plant Engineering. “There is With the general improvement of the econno overcapacity, so it takes prior planning to omy, ongoing deregulation and renegotiated line things up for any given project. The supply trade agreements by the current administrachain does not allow for immediacy.” tion, the volume of project activity has taken “Due to the good economy we are challenged off, resulting in labor availability issues and with finding quality subcontractors,” says material cost increases, says Jens Ebert, SSOE Tamara Zupancic, director of marketing for The Group principal division manager. “The market Austin Company. “Clients are not revising their conditions have been driving owners to accelschedules, so we are being more creative in our erate project delivery schedules in an effort approach to meet client requirements.” to get in front of further constraints and rising Carefully planned, projects can go on time costs.” Unfortunately, says Ebert, to cut costs and budget. “The lead times on materials and clients increasingly push for projects with low- equipment are becoming slightly longer,” says er levels of engineering definition. Tammi McAllister, CRB associate, core team 0
38
FOOD ENGINEERING
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June 2020
leader. “The increased lead times are something we can account for as long as we know and can plan for them.” “Based on the size of projects, we are looking at subcontractors that can handle those projects and beginning discussions with them early to incorporate them as part of the team,” adds McAllister. “If we don’t engage subcontractors early, we run the risk of projects being delayed. Clients understand the market but look to us to manage the risk and keep them on schedule.” Today, processors expect A&E/C firms to take on a co-leadership role in and contribute accountably to a deliberate process of achieving the fastest, safest, most economic start-
up, says Tom Wiersma, independent A&E consultant. Most clients have the experience to anticipate and build into their thinking the impacts of a tight labor market and the bottlenecked availability of some fundamental building materials. Therefore, to get started on the right foot, most food processors are more comfortable than ever with engaging a preferred architectural and engineering firm or AEC mobilization consultant early in the pre-project programming and scope phases.
PREFAB AND MODULARITY To help compensate for labor shortages and simplify construction, many A&E/Cs
Reported new construction projects The following charts list new construction projects reported by respondents to the 2020 Plant Construction Survey. For expansion and renovation projects and charts listing all projects combined, visit www.foodengineeringmag.com/plant-construction
Company
City
State
121 In-Flight Catering
San Francisco
CA
7-Eleven
Bellingham
80 Acres Farm
Hamilton
Primary Product
Type
Sq. ft. (x1000)
Cost ($ Mil.)
A&E/C
Completion Date
RTE meals
New
50
15
CMC Design-Build Inc.
11/19
MA
Cold storage
New
15
2
CMC Design-Build Inc.
8/19
ON
Produce growing/processing
New
30
10/19
A Aalco Distributing
Ft. Wayne
IN
Beverage distribution
New
105
Actagro
Biola
CA
Agricultural enhancements
New
11
AgTech Scientific
Paris
KY
Hemp processing
New
2000
AgTech Scientific
Paris
KY
Hemp extraction
New
50
Ahold Delhaize
North Kingstown
RI
Meat
New
200
Alexandrion
Carmel
NY
Distillery
New
ARCO National Construction
8/19
EA Bonelli + Associates
19 12/19 12/19
100
Dennis Group
3/20
Epstein
19
Alpla
Bowling Green
KY
Contract bottler
New
Amazon UFF
Boston
MA
Cold storage
New
30
50 5
CMC Design-Build Inc.
10/19
19
Amazon UFF
Indianapolis
IN
Cold storage
New
30
5
CMC Design-Build Inc.
10/19
Amazon UFF
Las Vegas
NV
Cold storage
New
30
5
CMC Design-Build Inc.
2/19
Amazon UFF
Orlando
FL
Cold storage
New
30
5
CMC Design-Build Inc.
8/19
Amazon UFF
Philadelphia
PA
Cold storage
New
30
5
CMC Design-Build Inc.
8/19
CMC Design-Build Inc.
Amazon UFF
Raleigh
NC
Cold storage
New
30
5
Americold
Rochelle
IL
Cold storage
New
180
93
8/19
Appalachian Harvest Company
Morehead
KY
Greenhouse, produce
New
85
19
Archer Daniels Midland
Mendota
IL
Flour
New
250
6/19
June 2020
FOOD ENGINEERING
8/19
foodengineeringmag.com
39
43RD ANNUAL PLANT CONSTRUCTION SURVEY have been using a well-established practice that is commonplace today. The modular approach—much like pre-manufactured homes—is to build skids or ready-to-go equipment in a modular section, for example, a “CIP skid.” Just like modular electronics, these sections are plugged in and wired at the plant and are quickly operational, as they’ve already been built and tested at the shop. With the current set of 3D design tools and today’s automation equipment and simulation software, more prefabrication can be done off site, says Harlan VandeZandschulp, P.E., president of Gleeson Constructors & Engineers LLC. Offsite design and prefab at an integrator’s or machine builder’s location can help keep labor costs down and decrease the need for more skilled people at the construction site when they’re already hard to find. Company
City
Aurora Organic
Columbia
State
Primary Product
This modular approach isn’t just for automation or process equipment. “Whether modularizing building components, pipe racks or equipment skids, this prefabrication technique executes work in a more controlled environment,” says Catt. “This decreases risks to productivity, eliminates other potential negative impacts, and creates an additional work front. In many cases, modularization helps lower overall construction costs while improving quality and schedule.” “Office and utility areas of manufacturing facilities are prototypes for modular construction, but we are beginning to see more activity in all areas,” says Keith Perkey, VP—Food & Beverage Division, The Haskell Company. “We are also beginning to see more use of technology throughout the construction process. Augmented reality is being used for field quality checks to match design models to field Type
Sq. ft. (x1000)
Cost ($ Mil.)
New
127
100
A&E/C
Completion Date
A MO
Fluid milk
MSKTD
1/19
B Barrett Petfood Innovations
Little Falls
MN
Petfood
New
160
18
10/19
Ben E. Keith
New Brockton
AL
DC
New
425
100
9/19
Bi Nutraceuticals
Reno
NV
Botanical ingredients + D/W
New
140
3
19
Blue Diamond Growers
Modesto
CA
Nuts
New
55 290
BlueScope Properties Group/Coca-Cola
Apopka
FL
Beverage mfg/dist.
New
BlueScope Properties Group/Goya Foods
Apopka
FL
Cold storage
New
BNutty
Portage
IN
Peanut butter
New
E.A. Bonelli + Associates
20
ARCO National Construction
7/20
ARCO National Construction
6/20
16
8/19
Bowery Farms
Nottingham
MD
Leafy greens
New
85
20
BrightFarms
Etowah
NC
Packaged salads
New
280
21
CMC Design-Build Inc.
10/19
BrightFarms
Penn Twp.
PA
Produce
New
250
20
4/19
Buzz Food Products
Charleston
WV
Meat
New
10
0.5
Epstein
12/19
5/19
C Canada Royal Milk
Kingston
ON
Infant formula
New
350
E.A. Bonelli + Associates
19
Canada Royal Milk
Kingston
ON
Infant formula
New
272
MDG Architecture
19
Canada Royal Milk
Kingston
ON
Dairy
New
272
E.A. Bonelli + Associates
20
Carolina Botanicals
Tabor City
NC
CBD (hemp)
New
Centro Sperimentale del Latte
Franksville
WI
Probiotics/ingredients
New
40
FOOD ENGINEERING
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12/19 7/19
June 2020
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43RD ANNUAL PLANT CONSTRUCTION SURVEY installation; sensors are being deployed in the construction materials and the construction workforce to improve both quality and safety.” NEW VS. EXPANSIONS AND UPGRADES Food processors are raising the need to respond to consumer demands and are looking to increase production, change technologies and meet food safety regulations, says Tyler Cundiff, VP, business development—food and beverage market, Gray Construction. When possible, they want to reallocate existing space and make modifications. But sometimes, mods/upgrades to existing facilities may not be practical. Our survey found an increase in new projects in 2019. Can you feel the frustration of an older facility? If you have an aging warehouse or plant, you have to ask: Is it providing the capacity, performance and efficiency you need to Company
City
Champion Petfoods
Edmonton
State
Primary Product
make a profit today? Twenty years ago, it may have been sufficient, and now you wonder if it’s just not worth applying bandages anymore, especially with limited capacity and flexibility, “head knockers” and ancient automation equipment. Is greenfield a viable solution? “Clients are finding that the cost of upgrading/renovating their facility is not that far off from building new,” says Luke Waite, ESI Group USA regional manager. “They find they may have antiquated equipment or mechanical systems—or that current operations do not meet food safety requirements—that have to be updated, which can significantly drive the cost of an expansion/renovation project up.” A new facility allows clients a clean slate, so to speak, to meet the updated food safety requirements for product/people separation as well as sanitation, limiting any possible interruption of Type
Sq. ft. (x1000)
New
427 700
Cost ($ Mil.)
A&E/C
Completion Date
C AB
Specialty pet foods
Chewy
Salisbury
NC
Petfood fulfillment center
New
Chicago Vegan Foods
Chicago
IL
Marshmallows, vegan foods
New
Chick-fil-A
Cartersville
GA
DC
New
Claxton Poultry
Sylvania
GA
Poultry deboning, packaging
New
35
Wilmington
NC
Beverage distribution
New
174
Coca-Cola Co.
Houston
TX
Bottling and DC
New
980
Coca-Cola Co.
South Windsor
CT
Beverage distribution
New
201
Common Collabs
Knox
IN
Cold-brew coffee
New
60
Constellation Brands
Mexicali
MX
Beer
New
Cornerstone PB Holdings
Pine Bluff
AR
Poultry
New
O’Fallon
MO
Petfood
New
190
Creekstone Farms
Arkansas City
KS
Distribution center
New
41
CS Beef Packkers
Kuna
ID
Ground beef
New
San Antonio
TX
RTE foods
New
Lexington
KY
CBD ingredients
New
55
4/19
25
9/19
12
110
5/19 ARCO National Construction
8/19
Haskell
6/20
ARCO National Construction 22
11/19 12/19
Alberici, Gilbane
Cosmos Corporation
Cuisine Solutions
11/19
5/19
Coastal Beverage
Curaleaf
Gray
10/21 12/19 8/19
35
Gleeson Constructors & Eng. LLC 11/19 3/19
290
120
3/19
9
19
D Dakota Investments/Bimbo Bakeries USA
Tomball
TX
DC
New
20 28
Dandelion Chocolate
San Francisco
CA
Chocolates
New
Danone
DuBois
PA
Plant-based yogurt
New
42
FOOD ENGINEERING
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their existing production while meeting consumer demands, says Waite. If you’re a homeowner, you may have encountered this little “surprise” when you decide to renovate or upgrade, but on a plant-size scale, the added costs of bringing everything “up to code” gets pricey real fast. “When tackling renovations, companies are finding that upgrading plants requires upgrading to modern regulations and standards,” says Chris Jarc, P.E., vice president and manager of project management, Hixson Architecture & Engineering. “If you are renovating an older plant, you are now required to consider accessibility (ADA) issues like employee welfares, path of travel and toilet facilities,” says Jarc. “Additionally, energy codes have become more restrictive, and building officials are requiring the new codes be followed: There is no “grandfathering” State
anymore. A 4,000-sq.-ft. renovation may end up requiring an additional 10% to 20% in costs to retrofit all of the regulatory-required items.” WAREHOUSES, DCs KEY TO TODAY’S ONLINE WORLD Changing consumer preferences certainly have had an impact on Haskell’s projects, says Perkey. In many cases the core production operation remains the same, but the packaging options and the warehouse and supply chain elements of the projects have changed to meet the current consumer demands. “Overall the volume of warehouses and fulfillment center activity has been strong and we certainly have seen increases in project opportunities in this arena,” says Perkey. “Customization and personalization are merging to give consumers very real ways to get
Company
City
Primary Product
Type
Sq. ft. (x1000)
Cost ($ Mil.)
Darigold
Boise
ID
Dairy bottling line
New/Ren.
26
16
Diageo
Lebanon
KY
Distillery
New
72
107
Domino’s
West Columbia
SC
Pizza dough
New
67
DOT Foods
Bear
DE
Cold storage
New
189
DuPont Tate & Lyle Bio Products
Loudon
TN
Warehouse/DC
New
A&E/C
Completion Date
D Epstein
3/21
Gray
6/21 20
ARCO National Construction
5/20 6/19
E EarthFresh
College Park
GA
Produce
New
140
300
22
7/19
F fairlife, LLC
Goodyear
AZ
Milk beverages
New
Farmer’s Select
El Paso
TX
Dairy
New
Florida Carribean Distillers
Winter Haven
FL
Cans
New
Flow Alkaline Spring Water
Verona
VA
Bottled water
New
Foremost Farms
Greenville
MI
Dairy
New
Stellar
7/19
EA Bonelli + Associates 300
3/21 16
58
Freshly
Savage
MD
Meal kits
New
171
Frito-Lay
Osceola Cty
FL
DC
New
286
Fuji Vegetable Oil Inc.
Avondale (New Orleans) LA
Palm, sunflower, coconut oils & DC
New
20
4/19 E.A. Bonelli + Associates
21 9/19
130
21
70
6/20
G Gathered Foods
June 2020
Heath
OH
Plant-based seafood
New
43
12/19
FOOD ENGINEERING
foodengineeringmag.com
43
43RD ANNUAL PLANT CONSTRUCTION SURVEY products they want,” says Woodard & Curran’s Snyder. The rise of Amazon has created demand for fast, efficient delivery. Big box stores have also survived and thrived. Mega food processors like Kellogg and Campbell are trying to find their niche in the changing retail supply chains. To achieve this supply chain flexibility requires complex warehouse operations that are in need of automation and ERP integration, says Snyder. E-commerce is playing a major role in the design and construction of distribution facilities, says Steve Tippmann, executive VP for the Tippmann Group. These facilities have larger footprints, and owners are trying to locate them more in urban sites, closer to where the population is, because deliveries now are expected in a day or less. “The demand for cold storage is very high,” adds Tippmann. “It’s hard for manufacturers to find storage space across the country, so now they’re starting to build new cold storage projects attached to State
Primary Product
their manufacturing plant, while cold storage providers are expanding more frequently.” “We have worked with many clients who sell directly to the consumer. This is definitely fueled by companies like Amazon who have the capability to take on the distribution of products if suppliers can get a substantial amount of product to their facility,” says Jennifer Redmond, marketing director of Food Plant Engineering. “This system affects warehouse needs because suppliers are increasing the frequency of shipments rather than requiring longer-term storage.” WASTEWATER TREATMENT AS IMPORTANT AS THE FOOD PROCESS Do you call the addition of a wastewater pretreatment or treatment facility to a processor’s campus new construction or an expansion? If one doesn’t already exist, adding one is certainly new, and while more money can be spent for an on-site wastewater pretreatment center
Company
City
Type
Gem State Dairy Products
Twin Falls
ID
Aseptic milk
New
GenCanna
Mayfield
KY
CBD ingredients for food
New
Sq. ft. (x1000)
Cost ($ Mil.)
A&E/C
Completion Date
G 3/19 100
40
3/19
General Mills/Blue Buffalo
McDonough
GA
Pet food distribution
New
9
2/19
General Mills/Blue Buffalo
Richmond
IN
Pet food
New
400
200
8/19
Glanbia
St. Johns
MI
Diary/cheese
New
375
555
8/19
10
Golfo di Napoli Dairy
Warren
IN
Organic cheese
New
3
Good Catch Foods
Columbus
OH
Prepared foods
New
40
Gordon Food Services
Westfield
IN
DC
New
500 180
Great Lakes Cheese
Wausau
WI
Cheese
New
Green Life Farms
Boynton Beach
FL
Leafy greens
New
Greenleaf Foods
Shelbyville
IN
Plant-based burgers
New
230
New
164
2/19 Food Plant Engineering, LLC
20 20
62
Dennis Group
5/19 5/19
310
20
H Haribo
Pleasant Praire
WI
Candy
Epstein
19
Heineken
Meoqui
MX
Beer
New
Hormel Foods
Omaha
NE
Sausage products
New
140
11/19
Horse Soldier Bourbon
Somerset
KY
Bourbon
New
26
19
Hunt Advantage Group
Paris
KY
Cold storage
New
44
FOOD ENGINEERING
foodengineeringmag.com
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55
ARCO National Construction
9/19
June 2020
ABOVE AND BEYOND ISN’T FAR ENOUGH. CON TAC T F ORR E ST MC N A B B TO LE A R N MO R E . 8 00.748 .4 48 1 OR V IS I T WWW.B IG - D.COM
43RD ANNUAL PLANT CONSTRUCTION SURVEY than a food processing line expansion, it certainly qualifies for a table entry on our yearly construction survey. In fact, Matt Williamson, director of engineering at ADF Engineering, says that on-site wastewater treatment continues to be a strong driver of capital spending. “The majority of our greenfield projects have been faced with difficult site challenges, including wetlands, poor soils and lack of existing utility infrastructure,” says A M King’s Dan Crist, VP of operations. “Many food processing facilities are being designed and constructed with onsite wastewater treatment due to inadequate offsite utility infrastructure and/or local AHJ (authority having jurisdiction) requirements.” And when a municipality has an existing wastewater requirement specification, it’s not uncommon for the municipality to set higher standards when it realizes that it can’t any longer handle the wastewater it’s getting. Alberici’s Oberlies is seeing an increase of wasteCompany
City
In-N-Out
Colorado Springs
State
Primary Product
water projects as municipalities place new demands on wastewater that existing pretreatment facilities can’t meet without upgrades. For a processor with a lot of wastewater, Black & Veatch’s Ziskind says the use of digestion technologies provides a triple win. A manufacturer can hit the trifecta of reduced wastewater costs, water reclamation and energy generation. What’s not to like about that? Smithfield Foods has been doing this for some time. TO BE CONTINUED While we’ve looked at the key issues—including COVID-19—facing food processors and A&E/Cs this year, there’s a lot more to cover. Be sure to watch for a follow-up story online where we will cover other design criteria and issues including FSMA, site-related issues beyond wastewater (such as weather and flood plains), trends in automation, and supply chains. Type
Sq. ft. (x1000)
Cost ($ Mil.)
New
100
47
118
A&E/C
Completion Date
I CO
Distribution center
Haskell ARCO National Construction
12/20
InterChange Cold Storage
Mt. Crawford
VA
Cold storage
New
International Farmaceutical Extracts
Danville
KY
CBD extracts, ingredients
New
6
19
International Farmaceutical Extracts
Danville
KY
CBD extraction
New
6
10/19
Interstate Warehousing
Anderson
IN
Cold storage
New
250
40
Tippmann Group
6/19
3/19
J J.M. Smucker Co.
Longmont
CO
Frozen sandwiches
New
432
215
Dennis Group
6/19
JBS USA
Ottumwa
IA
Pork
New
12
12
Epstein
2/21
Jet.com
Bronx
NY
Cold storage
New
185
20
CMC Design-Build Inc.
2/19
Jetton Biochemistry
Nampa
ID
Dairy powders
New
8/19
K KanPack
Arkansas City
KS
DC for fast food chains
New
203
KEG 1
Temple
TX
Beer DC
New
108
Kentucky BioScience International
Bowling Green
KY
CBD ingredients
New
Keurig Dr. Pepper
Allentown
PA
Beverage
New
811
Keurig Dr. Pepper
Moore
SC
Coffee
New
708
46
FOOD ENGINEERING
foodengineeringmag.com
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12/19
23
19
220
Dennis Group
9/20
Gray
8/21
June 2020
Company
City
State
Primary Product
Kingfish Zeeland
Type
Sq. ft. (x1000)
Jonesport
ME
Fish aquaculture
New
Kroger
Dallas
TX
Fulfillment center/DC
New
350
Kroger
Florence
KY
Fulfillment center/DC
New
674
Cost ($ Mil.)
A&E/C
Completion Date
K 110
11/19 22
17
1/19
121
10/19
Kroger
Forest Park
GA
DC/fulfillment center
New
Kroger
Groveland
FL
Warehouse/fulfillment
New
Kroger
Monroe
OH
DC/fulfillment center
New
335
55
8/19
New
200
20
12/19
6/19
L Lionchase Holdings
Texarkana
TX
Cold storage DC
Little Leaf Farms
Burnsville
NC
Fresh lettuce grow/production
New
86
12/19
Log Still Distilling
New Haven
KY
Bourbon, rye whiskey
New
12
8/19
Lotus Bakeries
Mebane
NC
Baked goods
New
130
Dennis Group
7/19
M Magnolia Botanicals
Ridgeville
CS
Hemp, CBD
New
Malt Products Corp.
Dayton
OH
Malted barley extract (dryer)
New
Maple Leaf Foods
London
ON
Fresh poultry
New
Maple Leaf Foods
London
ON
Poultry
New
Maple Leaf Foods
Shelbyville
IN
Plant-based Products
New
Mark Anthony Brewing
Memphis
TN
Specialty beverages
New
Martin Preferred Foods
Dallas
TX
Meat/poultry/seafood
New
McCain Foods
Burley
ID
DC
New
3.2 15 640
230
Caldwell
ID
Potato processing
New
100
Benton
KY
Meals
New
16
Michael Foods
Norwalk
IA
Eggs
New
150
Montréal
ON
Beer
New
Sparks
NV
Flavorings, extracts
New
Montana Specialties Mills LLC
Great Falls
MT
Non-GMO, organic oilseeds
New
MycoTechnology Inc.
Aurora
CO
Plant-based protein
New
6/21
310
Hixson Architecture & Engineering 23
12
3/19 Food Plant Engineering LLC
McCain Foods
MolsonCoors
6/19 Hixson/Gray CM
Hixson Architecture & Engineering 21
MegaFit Meals
Monin Americas
12/19
200
8/19
3
11/19
2/19
Gleeson Constructors & Eng. LLC 10/19 Alberici, Pomerleau
115
20
27
Gray
12/20 5/20
20 60
19 CRB
19
N National Property Holdings/Domino’s
Katy
TX
Dough, fresh ingredients
New
60
NC Food Innovation Lab
Kannapolis
NC
Plant-based foods
New
14
Nestlé Purina
Hartwell
GA
Pet food
New
ARCO National Construction 7
NewCold
Burley
ID
Cold storage for McCain Foods
New
180
90
Newly Weds Foods
Chicago
IL
Bakery
New
40
10
Niagara Bottling
Jeffersonville
IN
Water
New
469
56
11/20
CRB
19
Alberici
12/20
Epstein
12/20
19
19
Niagara Bottling
Kansas City
MO
Water bottling
New
420
68
9/19
Niagara Bottling
Temple
TX
Bottled water
New
450
90
4/19
NomNomNow
Nashville
TN
Fresh pet food
New
2
1/19
Nongshim
Corona
CA
Noodles
New
200
21
Nordic Aquafarms
Eureka
CA
Fish
New
400
5/19
June 2020
FOOD ENGINEERING
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47
43RD ANNUAL PLANT CONSTRUCTION SURVEY Company
City
State
Primary Product
Type
OFD Foods
Henrietta
NY
Freeze-drying contract service
Old Trapper Smoked Products
Forest Grove
OR
Jerky
Sq. ft. (x1000)
Cost ($ Mil.)
New
50
25
New
80
A&E/C
Completion Date
O 19 6/19
P Peer Foods
Edinburgh
IN
Cold storage
New
62
Performance Food Group
Gilroy
CA
Cold storage
New
14
Tippmann Group
5/20
190
ARCO National Construction
5/19
ARCO National Construction
Performance Food Group/Vistar
Mt. Olive
NJ
Cold storage
New
215
Performance Pet
Mitchell
SD
Pet food
New
150
Petsource by Scoular
Seward
NE
Pet foods
New
105
57
8/19 12/19
Gray
9/20
PHM Brands
Michigan City
IN
Hemp products/CBD
New
Plumrose USA
Moberly
MO
Pork
New
125
39
6 The Austin Company
3/21
Poultry Products Northeast
Londonderry
NH
Cold storage
New
110
20
CMC Design-Build Inc.
2/20
Prairie View A&M U Meat Processing Lab
Prairie View
TX
Meat processing
New
8
8 60
Preferred Freezer Services
Portsmouth
VA
Refrigerated warehouse
New
200
Prestage Foods of Iowa
Eagle Grove
IA
Pork
New
625
Proliant
St Johns
MI
Dairy
New
71
New
111
6/19
CRB
20 5/19
Epstein E.A. Bonelli + Associates
3/19 21
Q Quality Sausage QOZ
Dallas
TX
Toppings
Gleeson Constructors & Eng. LLC 4/21
QuikTrip
Belton
MO
Bakery
New
12
Haskell
19
QuikTrip
Midlothian
TX
Bakery
New
2
Haskell
5/19
New
50
R Rabbit Hole Spirits
Campbellsburg
KY
Bourbon, other spirits
Ramar Foods
Kapolei
HI
Filipino foods
New
Readington Farms
Easton
PA
Dairy
New
350
250
Ready Seafood
Saco
ME
Seafood
New
50
15
Resonate Foods
Lyon
KY
Food-grade hemp
New
19 12/19 4/19 CMC Design-Build Inc.
2
10/19 11/19
RiceWrap Foods
Butner
NC
Rice sheets for sushi
New
10
5/19
Rosina Food Products
West Seneca
NY
Meat products
New
58
10/19
Royal Canin/subsidiary Mars Petcare
North Sioux City
SD
Pet food
New
100
4/19
S Saratoga Food Specialties
Bolingbrook
IL
Dry mix (wastewater)
New
2 200
Scannell Properties/Northeast Coca-Cola
S. Windsor
CT
Beverage distribution
New
Sedes Soy Crush
Caruthersville
MO
Soy proteins/oils
New
Simmons Foods
Siloam Springs
AR
Chicken
New
300
Simmons Prepared Foods
Decatur
AR
Chicken processing
New
Principio
MD
DC
New
420
Smithfield Foods
Tar Heel
NC
Distribution center
New
500
Smith’s Food & Drug Stores
Henderson
NV
Dry-goods DC
New
Rome
GA
DC
New
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Epstein
3/19
ARCO National Construction
6/19 19
Smithfield Foods
Southeastern Mills
3
300
140
8/19 19 7/19
100
2/19
14
19
6
12/19
June 2020
Company
City
State
Southern Visions
Bay Minette
AL
SpartanNash
Fargo
SSI Foods Strauss Brands
Primary Product
Type
Sq. ft. (x1000)
Tea and sugar
New
125
ND
Produce DC
New
Amarillo
TX
Protein
New
Franklin
WI
Specialty meats
New
Cost ($ Mil.)
A&E/C
Completion Date
S
75
24
2/19
10
12/19
42
10/19 8/19
Stuffed Puffs
Bethlehem
PA
Stuffed Puffs marshmallows
New
150
12/19
Sunrise Soya
Delta
BC
Tofu
New
85
12/19
New
34
T Table Talk Pies
Worcester
MA
Cold storage
Tasty Brands
Owensboro
KY
Prepared foods
New
25
Taylor Farms
Ciudad Morelos
MX
Fresh cut produce
New
290
The Bel Group
Sorel-Tracy
QC
Mini Babybel cheese
New
The Muffin Mam
Watts Mills
SC
Baked goods
New
100
Torani
San Leandro
CA
Flavors, syrups
New
Trisco Foods
Colorado Springs
CO
Specialty foods
New
40
Tuffy’s Pet Foods
Delano
MN
Pet treats
New
173
Two Rivers Fishery
Ballard Cty
KY
Fish (12-company partnership)
New
Tyson Foods
Eagle Mountain City
UT
Case-ready beef/pork
New
June 2020
Tippmann Innovation Food Plant Engineering LLC 65
Dennis Group
5/19 20 1/19
66
20
19
7/19
12
Haskell
3/20 2/19
CRB
20 5/19
300
FOOD ENGINEERING
10/19
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43RD ANNUAL PLANT CONSTRUCTION SURVEY Company
City
State
Primary Product
Type
Sq. ft. (x1000)
Tyson Foods
Humboldt
TN
Fresh poultry
New
393
Tyson Foods
Joslin
IL
Beef
New
86
Tyson Foods
Tonganocie
KS
Poultry production
New
Cost ($ Mil.)
A&E/C Gray
Completion Date 11/19
Gleeson Constructors & Eng. LLC 4/21 320
6/19
U United Dairy Farmers
Cincinnati
OH
Donuts
New
Hixson Architecture & Engineering 19
V Victor Hoppenstein’s Brewlab
Charleston
SC
Beer
New
1
9/19
VPX (aka Bang Energy)
Pembrook Pines
FL
Energy drinks warehouse/DC (Ph. 1) New
35
2/19
VPX (aka Bang Energy)
Pembrook Pines
FL
Energy drinks warehouse/DC (Ph. 2) New
40
1/20
VPX (aka Bang Energy)
Phoenix
AZ
Energy drinks and DC
10/19
New
397
200
New
10
13
W WholeStone Farms
Fremont
NE
Pork
Epstein
5/22
WholeStone Farms
Fremont
NE
Pork
New/Ren.
36
7
Epstein
2/20
WholeStone Farms
Fremont
NE
Pork (wastewater)
New
14
22
Epstein
5/22
WholeStone Farms
Fremont
NE
Pork
New
10
10
Epstein
11/19
Wildbrine Plant-based Creamery
Santa Rposa
CA
Plant-based products
New
20
4
5/19
Z Zucarmex
50
San Diego
FOOD ENGINEERING
CA
foodengineeringmag.com
Liquid sugar processing
New
16
Haskell
8/20
June 2020
FA M FOOD AUTOMATION AND MANUFACTURING
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Expo Opens
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SOLUTIONS THEATER BREAKOUT SESSIONS
MONDAY, SEPTEMBER 14 Welcome
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ENGINEERING KEYNOTE: Engineering 101: Managing the Managers Joe Zembas, Senior Manager, Reliability Engineering, The J.M. Smucker Company Sponsored By:
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Casual Dinner: Floridian Flavor Extend conversations from earlier in the day while enjoying beverages, Floridian cuisine and a beautiful sunset.
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and CEO, Rebellyous Foods
Smucker Company
Plant Dynamics Unique to Emerging CPG Brands
Bringing Together OT and IT Hugh Roddy, VP of Global Engineering and Project Management, Chobani
Jasmine Sutherland, President, Texas Food Solutions Walter Nimocks, CEO, Just Made Juice David Ojobaro, Founder, Squeezed Online
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MONDAY, SEPTEMBER 14
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3:30 PM – 4:00 PM
10:15 AM – 10:45 AM
Track A: The Future of Conveyor Drive Hygiene
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Presented By:
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Track B: Automation thru WorkFlows and Advanced Analytics Presented By:
4:05 PM – 4:35 PM
Track A: Path to Digital Transformation in Foods and Beverages
10:50 AM - 11:20 AM
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Today, there is an increase in scrutiny that food companies face regarding the production of high-quality water, the removal of forever chemicals, and the need to continually meet discharge permit limits for wastewater. The use of temporary water treatment solutions is an effective way to ensure that specific water quality parameters are consistently achieved.
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In this webinar, we will share water treatment solutions for the removal of forever chemicals, take an in-depth look at a dairy wastewater application to prevent overspill of their retention ponds and a food facility’s solution for handling incoming water quality fluctuations and wastewater disruptions.
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INTELLIGENT
Maintenance From reactive to preventive to predictive to prescriptive, maintenance in food and beverage processing plants has come a long way BY SHARON SPIELMAN, SENIOR EDITOR
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June 2020
PHOTO COURTESY OF ABB
ABB Ability Connected Services for ABB robots monitor operations of single or multiple robots, triggering alarms at any operational disturbance.
F
ood and beverage processing ranges from receiving materials to production, quality assurance and inspection, and the packing and dispatching of final goods. All of this occurs in a very specific environment (harsh, humid, hot or cold, for instance), which requires continuous maintenance of equipment, storage and workspaces, according to Tatjana Milenovic, global head of food and beverage industry segment at ABB Inc., an industrial automation company. “Food safety and sustainable operations with minimal downtimes are the highest priorities,� she says.
June 2020
Big data and deep learning make artificial intelligence useful to understanding data, making predictions and suggesting recommended actions without explicit human instructions. There are three areas to consider with AI: process optimization, predictive maintenance and production efficiency, says Massimo Bonardi, technical and managing director/co-founder, Antares Vision, a solutions provider in inspection systems, track and trace, and smart data management. “The benefits are far-reaching, including shortened time to market, streamlined machine reconfiguration and reduced mechaniFOOD ENGINEERING
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INTELLIGENT MAINTENANCE Using AI allows for timely maintenance action, fewer incidents and faster issue resolution time.
REDUCING MAINTENANCE DOWNTIME WITH AI When it comes to maintenance in processing plants, having the data and knowing how to use it is the key to system upkeep. Failure is managed before it happens, by monitoring correlated data to find patterns and repeatability. “It’s an information cause-and-effect analysis, performed in near real time,” Bonardi says. “The better the maintenance predictivity, the more downtime can be reduced to benefit both output optimization and production schedules. A crucial factor is determining the ‘real-time’ condition of equipment rather than cal complexity—including reduced production guesstimating based on average, per-machine and maintenance costs,” he says. Preventive maintenance expectancy,” he says. maintenance is driven by metrics monitoring Traditionally, maintenance was done by reto avoid downtime that otherwise may have actively acting as equipment malfunctioned. been unforeseen. “Elements include every“Preventive maintenance was applied thing from production line sensors and quality to maintain and replace parts before they inspection controls to smart connections with failed, independently from their actual conelectronic recordkeeping and manufacturing dition,” Milenovic says. “The development of execution systems (MES).” the digital concept of predictive and condiAI can play a vital role in optimizing powtion-based maintenance allows food proceser and water consumption, which creates sors to plan maintenance more efficiently, immediate benefits for environment, operat- reducing downtime due to broken parts and ing costs and margins, Milenovic adds. “For eliminating maintenance work which is not instance, fresh products like fruit and vegepresently needed.” tables can vary dramatically in size, shape, Often residing in different systems, maincolor or texture, adding a layer of complexity tenance data typically is fragmented and to the production line. AI solutions can easily non-interoperable. “With the emerging trend recognize variances, removing contaminants toward data being aggregated in centralized without wasting whole batches and continu- asset management databases and enterprise
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June 2020
PHOTO COURTESY OF ABB
ally adjusting water and energy usage according to requirements. The entire process, including robotics, can be fully automated, running 24/7 and active across production,” she says.
INTELLIGENT MAINTENANCE resource planning (ERP) systems, available maintenance data is able to be leveraged in AI-enabled activities like perceiving the surrounding environment, applying reasoning to the data context and making optimal maintenance decisions,” Milenovic says. Jim Renehan, senior marketing manager for WIPOTEC-OCS, a manufacturer and supplier of in-motion weighing and X-ray scanning equipment, says, “We are seeing a high degree of automation, that sometimes incorporates modular plant construction, but it is very rare that we see holistic concepts in the sense of smart food and beverage processing plants. There seems to be a fair amount of
PLANTS MONITOR DATA FOR PATTERNS AND REPEATABILITY, ANTICIPATING MAINTENANCE FAILURES BEFORE THEY HAPPEN.
skepticism on the plant floor when it comes to AI. However, the food processors that we work with in general are standardizing their processes via ERP and MES.” While predictive maintenance uses sensors to precisely collect data regarding equipment condition and overall operational state to predict when a failure will occur, the use of AI in the maintenance domain elevates the function to that of prescriptive maintenance, Milenovic says. “Failures are not only anticipated, but actions are also recommended. The potential outcomes of the recommended actions are then processed and projected.” For example, a sensor-based predictive concept for a motor or bearing will indicate when the equipment is likely to fail given its temperature and vibration profile. “The prescriptive June 2020
method will indicate the relation and impact between motor temperature and speed, and suggest, for example, to reduce speed by 10% to achieve 30% more working hours before the equipment is likely to stop,” she says. Through predictive analytics, algorithms and AI, maintenance people are becoming increasingly empowered to perform maintenance with a more exhaustive approach, Milenovic says. Bonardi adds that the latest AI developments are simply more sophisticated, capable of uncovering a deeper understanding of the overall manufacturing environment and its individual parts. “The impressive amount of available data needs to be understood and managed, toward the goal of translating them into meaningful production improvements and automation; predictive maintenance is a critical subset of this comprehensive goal, as it plays an outsized role in limiting machine downtime,” he says. Prateek Joshi, CEO at Plutoshift, a performance monitoring platform provider, adds that because food and beverage processors are increasingly digitizing their operations, that allows them to collect operational data and store it in an organized way. “But this data is not being used to get their work done,” he says. “The operators still rely on manual workflows (e.g. spreadsheets) to do work, which means they are working in a reactive way as opposed to a proactive way. AI can be leveraged to automate these workflows and transform to a more proactive way of working,” he says. “The positive trend within this market segment is that the C-suite leaders are showing strong commitment toward data intelligence and automation.” Bonardi says AI is integrated with the Antares Vision line performance monitoring system, and maintenance represents a key value FOOD ENGINEERING
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INTELLIGENT MAINTENANCE
in production process, able to make a difference in efficiency challenges and KPIs. “Just to make an easy example, if after 10,000 rpm we need to change the conveyor belt in a production line, the line is going to be stopped, there will be a cost related to downtime, to the production stop, to the spare parts replacement,” he says. “But it’s instead key to be able to predict any breakup, collecting data and training via neural networks to monitor the relevant parameters, when some of them, for example temperature and vibration, become crucial. For this reason, we gather different kinds of data—from production line sensors, quality
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inspection controls, in connection with ERP and MES.” According to Milenovic, the application of sensors for monitoring various equipment parts (motors, bearings, pumps, etc.) is a first step toward predictive maintenance. “For example, ABB smart sensors monitor temperature, vibrations and other parameters of a motor, sending alerts to initiate timely maintenance action before any downtime occurs,” she says. “ABB Ability Connected Services for ABB robots monitor operations of single or multiple robots, triggering alarms at any operational disturbance (e.g., a robot slows down), enabling timely maintenance action, fewer incidents and faster issue-resolution time, resulting in far less downtime for more hours at peak production,” she says. AI powered sound monitoring to detect and predict equipment failures is gaining traction in food processing plants too. “‘Listening to machines’ is utilized to monitor equipment operations and react quickly in the case of a detected problem, helping to classify the problem and initiate timely action to prevent unplanned downtime. It is a good practice not only on standard processing lines, but also with dangerous equipment to prevent employees from having to June 2020
PHOTO COURTESY Of WIPOTEC-OCS
WIPOTEC-OCS offers an enhanced washdown system for its SC-WD-6000-B X-ray scanner. Capable of inspecting many tons of bulk meat per hour and offering foreign body detection sensitivity, the scanner is equipped with an HD-TDI camera detector. In conjunction with the metal-ceramic tube, it generates extremely high-resolution X-Ray images for the unit’s custom-designed image processing software.
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INTELLIGENT MAINTENANCE stop or directly access the processing line,” Milenovic adds. She says that one can look at “listening to machines” as a first line of defense for maintenance, as it can detect failures earlier than other technology. “The combination of sophisticated AI and cameras has applications in the area of worker safety (e.g., ensuring required safety gear is used by operators),” she says. ADDING SENSORS TO MONITOR MOTORS, BEARINGS, PUMPS AND OTHER EQUIPMENT IS A FIRST STEP TOWARD PREDICTIVE MAINTENANCE. Bonardi says to switch from preventive to predictive maintenance empowered with AI, first connect with data management software. “AVionics landscape allows gathering data from different equipment and to integrate with existing data source (such as ERP, MES),” he says. Then look at IIoT in production lines, including temperature, cameras,
CHALLENGES FOR AI IN MAINTENANCE “The most common challenge of artificial intelligence is taking full advantage of its power,” says Bonardi. “The impressive amount of available data needs to be understood, managed and translated into improvements in automation to release the humans from complex jobs and mistakes, or to help them make better decisions. The combined effect of automatic learning from data, images, examples, texts, etc., together with sophisticated learning models and the high computing capacity, has yielded tremendous opportunities for progress.”
Capable of handling up to 250 products per minute, the HC-M-WD-MDi checkweigher uses WIPOTEC-OCS’s electromagnetic force restoration (EMFR) technology and has an intuitive software interface. It meets all food processing industry requirements, including IFS-compliant product control and other HACCP or LMHV/FDA hygiene regulations.
PHOTO COURTESY Of WIPOTEC-OCS
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vibrations, readers, microphone or integration with existing sensors. Empowerment by AI includes data experience collection for training the neural networks and to find the patterns and correlations between relevant parameters. The final step is service for continuous updating of the neural network. He adds that the four main reasons to switch from preventive to predictive maintenance with AI include monitoring KPIs; more accurate time to maintenance; cost saving in spare parts and equipment maintenance based on statistics; and integrating with other systems, like ERP software, to get a full picture of performance.
FOOD ENGINEERING
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June 2020
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INTELLIGENT MAINTENANCE Bonardi says an important element to consider is that the AI tools are fed by experience provided through examples. That means their performance is tied to how representative
USING AI WITH DATA MANAGEMENT SOFTWARE ELEVATES PREVENTIVE MAINTENANCE TO A PRESCRIPTIVE APPROACH. the dataset used to train them is. Therefore, even though AI is enabling previously inaccessible applications, AI-based systems require constant monitoring and frequent updates, in order to support the changing nature of real-world processes. He identifies two important gaps related to the use of AI for mission critical applications:
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• The need for technologies that enable new business processes supporting the collection of in-process knowledge (data refinement) and the deployment of large-scale neural networks on-premises. • The absence of adequate tools to monitor the performance of deep neural networks in production; in the face of unexpected or unrepresented inputs in the training dataset, the current AI systems are not equipped to “stop” or provide a direct estimate of the reliability of their predictions. Renehan says that big data and plant floor acceptance of AI are the two biggest challenges. “With big data automated and tool-assisted acquisition, evaluation and analysis of manufacturing data is a must for the food processor wishing to implement Industry 4.0 and AI. However, checkweighers and X-ray scanners generate a massive amount of useful data given the production rates of today’s food and beverage processors. The food processor needs to have the network hardware and software solution that is just right for their unique situation,” he says. “The acceptance of AI at the plant floor level can only come about with a concentrated effort on the part of the food processors to adequately train their staff. Also the AI implementation needs to make sense to the workers.” June 2020
INTELLIGENT MAINTENANCE When it comes to the challenges for facilities that use predictive maintenance, Renehan says the biggest challenge to predictive maintenance is to effectively use the process data that today’s factory floor machines, such as checkweighers and X-ray scanners, provide. “Oftentimes, we see these machines being underutilized due to infrastructure limitations within the processing facility,” he says. Bonardi says that unifying and managing massive amounts of data is the key to powering the next generation of e-commerce, tracking, fraud detection, supply chain and logistics applications. “Complex architecture like in the food and beverage sector are difficult to run, including machinery, production lines, government compliance, suppliers (brand owners, private label
manufacturers, repackagers, etc.), warehouse, wholesale distributors and logistics. A primary need is a software ecosystem designed to manage the massive data storage and the information flow.” For this reason, he says it is essential to ensure the maximum data safety, the flexibility in different communication requirements, the minimum downtime for software updating and patch releases, and a unique point of connection to enable interface with different players, software and hardware solutions. For more information: ABB, Inc., www.abb.com Antares Vision, www.antaresvision.com Plutoshift, www.plutoshift.com WIPOTEC-OCS, www.wipotec-ocs.com/us
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for Simply pets the best
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Pet food shoppers, especially people seeking premium products, are paying more for packaging that’s more sustainable, has an upscale look, or comes with convenience and freshness features.
Packaging is king in the growing market for premium dog and cat food, helping showcase quality, safety and sustainability BY ROSE SHILLING, MANAGING EDITOR
the best food you can afford, you really don’t want it to get stale or spill from an open bag. Flexible packages and lighter containers with premium protection and HD printing help processors tap into booming pet ownership and react to trends like wet treats, high protein content and CBD supplements. As U.S. pet food production has become safer under FSMA, packaging reflects transparency, showing the food through windows and highlighting natural ingredients. Bill Kuecker, vice president of marketing, Mondi Consumer Packaging, says people are increasingly assigning animals human characteristics and that has played a role in the market for pet food and its packaging. “As the social contract changed and treating a pet as a true family member has become more of a social norm, growth and development of the premium pet food category have emerged as a natural outcome,” he says. “With the tremendous growth of premiumization, ackaging has a key role in the pet food the entry of new brand players and a SKU industry’s robust growth, especially for explosion have triggered seismic packaging premium products. The bag or container shifts across the pet food industry.” enables manufacturers to stand out with cat Owners take their pets’ wellness extremely and dog owners who want sustainable opseriously, and that means consumers are willtions, personalized pet diets and ingredients that even humans find appealing. (Think Texas ing to invest more in their pets’ food. As consumers are becoming informed in the science BBQ flavor.) Shoppers have shown they are willing to pay behind pet nutrition, brands are increasingly offering fresher, higher quality ingredients. In more for sustainable packaging and conveturn, this has led to the expansion of preminience features like handles and stay-fresh zippers. When you buy your beloved dog or cat um and specialty pet food options with many
PHOTO COURTESY OF GET T Y IMAGES
P
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SIMPLY THE BEST FOR PETS Ultra-high definition flexographic printing capability from Mondi offers rotogravure-level image quality.
WHAT BRANDS WANT With so many different pet food varieties on the shelves, brand owners are looking to new SKUs hitting the shelves of premium pet differentiate themselves with brighter colors, retails and mass grocery stores, Kuecker says. high-end graphics and a variety of resealable Maria Halford, vice president of global closures, Halford says. Whether it be formats marketing, ProAmpac, says many pet owners such as pouches and quad-seal bags, stand enjoy participating in preparing their pet’s out graphics or unique finishes and printing meals, just as they prefer to “finish” meals at techniques, brands are looking for that crehome for their families instead of only serving ative “pop” on the shelf. prepared foods, she says. ProAmpac has been meeting this need with To that end, there’s been a rise in packaging its Signature Surfaces line of surface enhancesolutions for high-protein content, refrigerated ments for flexible packaging materials that and frozen options, as well as “gravy toppers” includes: Paper Touch, Soft Touch Matte and for dry kibble, she says. “As the food ingrediRegistered Matte. The finishes offer visual and ents improve, the packaging needs to adapt.” tactile experiences for consumers and proFor example, shelf life, moisture, grease, vide brand owners additional opportunities to flavor and density are all critical factors in stand apart in the retail environment. engineering the packaging material structure. A Mondi survey affirms how important sustainBeyond the material, packaging format is also able options are. The company teamed with Dow a key differentiator, she says. Chemical in 2019 to study premium pet food Distribution, retail facing, portability, dispens- purchasing trends and behaviors that pet food ing and reclose are important factors contribproducers can use to earn consumer preference.
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P H O T O C O U R T E S Y O F M O N D I C O N S U M E R PA C K A G I N G
uting to the design of the packaging format. For example, where polywoven bags work well for large packages of dry kibble, a reclose quadseal bag is more appropriate for a premium product being displayed on a store shelf. Innovation is key for brand owners and consumers who are more discerning than ever, she says. They want anything from materials that run faster on filling equipment, to options that offer increased convenience, dispensing and ease of use, to recyclable and sustainable options. “As the pet food industry continues to grow, so do the demands on packaging companies to offer differentiated and functional solutions,” she says.
C H A R T C O U R T E S Y O F M O N D I C O N S U M E R PA C K A G I N G
Packaging scored prominently on five occasions when Mondi and Dow Chemical asked buyers of premium dry pet food about important features.
P H O T O C O U R T E S Y O f P R O A M PA C
About 75% of respondents “feel more favorably toward a brand with sustainable packaging,” the research found. In today’s hyper-competitive pet food industry, brands are seeking solutions that complement their corporate values, with sustainability being a case in point, Kuecker says. An example of this is Mondi’s BarrierPack Recyclable. The plastic laminate for premade pouches and FFS roll-stock is recyclable in areas where flexible packaging is accepted and through store drop-off. This is done without compromising the functionality. The packaging features that brands request start with the consumer, and their preferences show the key role that packaging plays in premium pet food commerce, Kuecker says. For example, a primary finding of Mondi and Dow’s
survey was in the purchasing factor category, where packaging lagged behind product quality, but was on an equal footing with brand and marginally behind price in terms of influencing purchasing behavior. The significance of packaging in the marketing mix prompted pet food manufacturers to partner with Mondi to create pet food packaging that is easier to carry, open and reclose, and that features highly readable print, Kuecker says. Clear
ProAmpac’s premium pet food solution, QuadFlex, has a quad-seal design with ideal shape, strength and shelf presence, along with plenty of branding space. The company recently introduced a recyclable version.
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SIMPLY THE BEST FOR PETS and readable at-a-glance print helps convey nutritional information that is of paramount importance to consumers concerned with their pets’ nutrition. Brands are also looking for packaging that retains its functionality and consumer appeal in a demanding supply chain environment, and enables efficient manufacturing throughout the fill and ship process, he says. PICK YOUR PACKAGING From an operational perspective, the packaging must be compatible with the filling equipment and supply chain to meet the manufacturer’s efficiency needs. Early conversations with customers help Mondi experts navigate potential trade-offs among functionality, cost and sustainability, Kuecker says. To help brand owners make critical packaging decisions, ProAmpac also ensures up
front which designs can be commercialized in the short term on existing infrastructure and which may take more time or customized equipment to produce or fill, Halford says. “This integrated approach helps our customers make the best decisions for their brand both thoughtfully and quickly, ensuring they stay ahead of the competition.” ProAmpac is careful not to recommend design elements that require long lead times that are outside the brand’s launch schedules, which could include specialty filling equipment, packaging production equipment or extended drop/shelf-life testing. “Focusing our customers on readily available solutions results in faster commercialization while minimizing frustration due to complexity.” Many innovations are centered around three basic themes: sustainability, functionality or convenience and differentiation, she says.
FRESHPET: AN EXAMPLE OF THE GROWTH THAT PACKAGING MAKERS ARE CHASING
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Freshpet is a prime example of the pet food market segment that focuses on natural, fresh foods that meet sustainability and safety goals.
location to help us drive new innovation while making our food in a way that’s best for pets, people and the planet,” said Billy Cyr, CEO of Freshpet. June 2020
PHOTO COURTESY Of CRB
CRB will develop Freshpet’s third kitchen for fresh, refrigerated pet food with a design undistinguishable to human food processing lines, appealing to shoppers who want pet food that’s as safe as what they eat. The new facility in Ennis, Texas, will incorporate layout efficiencies, hygienic segregations, equipment, conveyance, cleaning and inspection designs that are indistinguishable from human food processing facilities, the engineering, architecture and construction company says. The kitchen will allow Freshpet to significantly scale production capacity as buyers increasingly seek fresh and natural food for their pets. “Our third Freshpet Kitchen in Ennis is the perfect
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The JLS Automation case loader uses robotic pick-and-place to load products into packages and packages into cases.
There’s a lot of information available showing that consumers will pay more for most of these attributes. In general, new product launches provide the opportunity for these attributes and the associated cost. It’s the products that have been in the market for a long time that make it more difficult to add features or sustainability that increase the cost, she says. PICK YOUR PACKAGING MACHINE A range of versatile packaging machines help accomplish the variety of formats for the growing pet food options. For example, Reiser’s packaging solutions cover many pet food
applications, from small chubs to preformed trays with features including elaborate shapes or snap-on lids. Reiser’s Ross line of tray sealers include
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SIMPLY THE BEST FOR PETS startup/R&D-sized machines through the range of models to very high output applications, offering tray de-nesting, autoloading, packoff systems and more, says Mike McCann, Reiser packaging specialist. The company also provides thermoform/fill/seal solutions through its Repak and Variovac lines, handling rigid formed packs, as well as flexible formed packs. The Reiser Rapid Air Forming systems allow the company to run all applicable film structures, creating film-saving packages, without the need for complex and expensive forming tooling, McCann says. Films with clarity, colors, registered printed graphics, microwavability, biodegradability, various barrier combinations, peelability, zipper attachments, standup pack designs, innumerable handle style features, etc., all run simply on Reiser’s machines. “Simplicity, sustainability, greener are all of the buzz going forward on film choices,” he says. Many “carrier packs” are in the form of zipper standup pouches with four-side graphics, handle features and other elements. Reiser can also run these using its Supervac line of inline bag sealing and evacuation systems, to streamline hand-fed systems into semiautomation. Reiser’s JLS robotic packaging solutions are invaluable, June 2020
especially for e-commerce needs, McCann says. Processors can use simplified, consolidated internal pack sizes of components (standardized
to reduce changeovers) and simplified less costly films (for graphics on boxes and instruction sheets), facilitating JLS pick-and-place to load
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SIMPLY THE BEST FOR PETS product robotically into the packs and load packs robotically into the case. This is usually done with Reiser’s thermoform/fill/seal equipment, he says. WHAT’S NEXT? The sustainability trend will certainly continue to grow in importance, Halford says. “Brand owners are working toward greener solutions and want packaging to fill the market gap with recyclable options.” Along with sustainability, increased functionality and shelf appeal remain important, she says. Improving the billboard on the shelf has provided growth in the company’s QuadFlex packaging. Mondi is continuously looking for innovations that help achieve new levels of packaging cost and efficiency, within an overall framework of sustainable achievement, Kuecker says. The Mondi/Dow survey results highlight continued needs for product freshness, packaging convenience and shelf appeal. “As brands and pet food manufacturers partner with innovative packaging companies like Mondi, consumers will enjoy more package size options and handling conveniences in recyclable or otherwise increasingly sustainable packaging,” Kuecker says. To help facilitate this, Mondi has in place EcoSolutions, its customer-centric approach that helps brands and pet food manufacturers achieve their current and future sustainability packaging goals. “Without question, sustainability will remain a primary consideration in the design and development of pet food packaging moving forward,” he says. For more information: Freshpet, www.freshpet.com Mondi, www.mondigroup.com
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Robot uprising How processors can use robots to enhance food quality and safety BY RICHARD F. STIER, CONTRIBUTING EDITOR
W
hen most people think of robots, they tend to think of a metallic humanoid from science fiction. But robots or robotics are more than humanoid creations. We can thank Isaac Asimov for the creation of the term robotics back in 1941: The branch of technology that deals with the design, construction, operation and application of robots. Specially built robotic machines have evolved to fill many niches. Any kind of machine automation may be deemed robotic. The question is: How are robots used in the food industry and what might the future hold for the industry? There are many food processing operations where robots are applied:
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1. Receiving 2. Warehousing 3. Processing 4. Quality 5. Casing and packing 6. Shipping 7. Sanitation 8. Sampling and testing Let’s follow the process flow from field to consumer to look at how robotics may be applied to food production, processing and handling. AGRICULTURE Robotics are used for two basic agricultural applications: growing and harvesting. Some farmers are now employing robotics sensors June 2020
PHOTO COURTESY OF GET T Y IMAGES
Packaging is one of the top jobs for robots in food factories, eliminating a repetitive task for humans.
to monitor different variables essential to efficient food production. The sensors may be used to monitor such parameters as soil moisture, soil acidity and temperature. With more and more farmers adopting drip irrigation technology, the sensors may be linked to the system to deliver water and nutrients as needed. These systems are designed to ensure more efficient operations. Growers have utilized mechanical harvesting systems for many, many years. This could be considered a robotics application. Mechanical harvesters have certain drawbacks in that they may collect nonfood items. I have personally seen some of the foreign materials that come in with mechanically June 2020
harvested products, including snakes, glass, metal, stones and many others. Processors purchasing mechanically harvested material must install systems, such as air blowers, float tanks and magnets, to catch contaminates. FOOD PROCESSING APPLICATIONS Robotics advocates like to talk about potential advantages of using robots in food processing applications. They mention that robots can work in harsh environments that would be uncomfortable for humans, that robots are sanitary and can be “sterilized� (which is the wrong word) and can work more safety. These advantages are all true, except for the comment about sterility. Any robotic system that FOOD ENGINEERING
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designed robotic hands and arms that gently grab different products and place them into the appropriate package. These systems are currently being employed in produce operations, snack foods, bakery touches foods needs to be deitems and proteinaceous signed so that it can be propproducts, such as fish and erly cleaned and sanitized. meats. The robotic systems The 10 principles of sanitary are faster than humans, and design established by the American Meat there are no concerns about reInstitute must be applied to any equipment petitive motion injuries. One of the manumanufactured for use in food processing. facturers of this technology is a company called Among the current applications for robotics Soft Robotics Inc. (www.softroboticsinc.com ). in food processing are meat processing, sortThese systems can even be adapted to handle ing, food handling (especially fruits, vegetables leafy greens, such as romaine lettuce, which was and leafy greens), and very specific applicaimplicated in several foodborne outbreaks. Elimtions, such as cake decorating. Meat process- inating the human element could help minimize ing is an interesting application in that meat the potential for cross-contamination. is extremely variable in size, shapes, marbling One of the best applications for robotic and fat distribution. The meat application, systems is sorting for quality or other attritherefore, focuses on beef carcass butchering butes. Sorting technology has made incredible rather than preparing cuts for retail sales. The strides in recent years. Sorters utilize lasers driving force in this application is in part work- and various kinds of optics to detect defects. er safety. The human effort involved in butch- Optical sorters can do things like count the ering carcasses is considerable, and the tools slices of pepperoni on a pizza, be programmed needed are potentially hazardous. Butchers to remove materials that are different colors, work in a cold environment and must wear or utilize different wavelengths of light to the appropriate garments to keep warm and eliminate specific defects. Multispectral analyessential personal protective equipment to sis has been utilized to detect grains, seeds protect themselves from injury. and nuts that have been contaminated with Another potential application for robotmycotoxins. As an example, aflatoxins will ics involves gripping and moving or placing fluoresce under ultraviolet light, allowing condifferent food products. Companies have taminated nuts, such as almonds or peanuts,
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PHOTOS COURTESY OF BĂœHLER
One of the best applications for robotics is sorting. BĂźhler created LumoVision to find and remove cancer-causing, aflatoxininfected grains.
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ROBOT UPRISING to be removed from the process flow. The European equipment manufacturer, Bühler, has developed a system called the LumoVision that utilizes this technology (https://digital. buhlergroup.com/lumovision). Mycotoxins, such as aflatoxin and fumonisin, are products of fungi metabolism and have been associated with the development of cancers in persons exposed to these metabolites over time. Being able to remove contaminated seeds, grains or nuts will enhance human health globally. Perhaps the most common and most effective use of robotics in the food industry is in packaging, casing and palletizing. These actions of repetitive, and hence, very applicable to being automated. An automated or robotic packaging system can form the packing case, fill it with the item being cased, seal and code the case, and then lift it to the awaiting pallet.
Depending upon the product being produced and the size of the case, the system will be programmed to build the pallet utilizing a designated pallet pattern. If one is packaging a frozen product, such a pallet might be designed with windows to allow better movement of cold air. Canned foods or snacks might go into a square or rectangular pallet pattern. This kind of repetitive motion that a robot does so effortlessly is the type of activity that often results in repetitive motion injuries for the crew working at casing and palletizing. These systems can also be designed to automatically feed pallets to the palletizer. Human intervention is often limited to getting the stretch wrap machine started by inserting the wrap between two rows of cases. Some companies such as Frito-Lay have robotic systems for transporting and storing pallets in the warehouse. The
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transporters are slow-moving crawlers that follow preprogramed paths and are also programed to stop if they sense someone or something in their way. Statistics show that the use of robotics in food processing is increasing at a rate of approximately 17% a year. The best potential applications for robotics are those that involve repetitive motions or actions and deal with products that are somewhat uniform. With increasing computer power and the expansion of artificial intelligence (AI), the application of robotics in the food industry will continue to expand. Will we ever get to the point that robotics will completely replace human beings in food processing? There are some operations that have evolved to the point where there are only a few persons needed to run the facility. An example might be the bakeries making buns for McDonald’s. But there are no fully automated food processing plants, and it will probably not become a reality for at least another generation. Asimov’s world of robots is still far in the future.
Decreasing human handling of food reduces risk of cross-contamination.
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FOCUS ON SHARON SPIELMAN SENIOR EDITOR
contaminant detection
Following the greenest path
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hen Nature’s Nikhil Mehrotra, Path Foods de- packaging Engineer cided to offer its prod- at Nature’s Path, says upgrading its case ucts in large standpacking equipment up bags and folding with Syntegon cartons of up to 44 oz. (1.25 kg) for whole- Technology helped reduce its cardboard sale warehouse clubs consumption. and supercenters, the company reached out to Syntegon Technology (formerly Bosch Packaging Technology). The Vancouver-based cereal and superfood manufacturer offers organic and planet-friendly products while using more environmental-
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ly friendly packaging. By upgrading its case packing equipment, the company reports it has significantly reduced cardboard consumption and boosted production efficiency. Although market factors and consumer trends influence company processes, they are not the only driver, according to Nikhil Mehrotra, packaging engineer at Nature’s Path. “Every decision we make must align with our triple bottom line—being socially responsible, environmentally sustainable and financially viable. In 2010, we became zero-waste certified and pledged to become completely carbon neutral by 2020. This step consequently entailed looking at the environmental impact of our packaging,” Mehrotra says. As a result, the company strives to use its packaging material as efficiently and effectively as possible. Nature’s Path worked with Bosch Packaging Technology, now Syntegon Technology, for a number of years, starting with a complete packaging line for cereal bars in Blaine, Wash., in 2012. Over the years, the company expanded its production capacities to accommodate its growing 100% organic product range, including cereals, oatmeal and granola, says Mehrotra. June 2020
P H O T O S C O U R T E S Y O F N AT U R E ’ S PAT H
Case packer from Syntegon helps Nature’s Path stay true to environmental mission
DRY PROCESSING TECHNOLOGY
FORMAT FLEXIBILITY With a goal of finding case packing solutions for production sites in Sussex, Wis., and Blaine, Wash., that would address the challenge of packaging delicate products into large, household-size packs—which can be tricky in terms of filling level, bag roundness and form stability—the packReducing cardboard aging experts suggested the Elematic 3001 EFFICIENT FORMAT use is part of the goal WA wraparound case packer for medium CHANGES for Nature’s Path to and large sizes for the Wisconsin site. The The Elematic 3001 become carbon machine cartons 11.5 oz (325 g) and 35.25 oz WA allows for loading neutral this year. (1 kg) boxes of cereal. blanks into the maThe Washington production site needed chine ergonomically a new cartoning solution for boxes of cereal and hasslefree. The case packer’s open and bars, so Nature’s Path purchased the Eleasy-access framework boosts visibility ematic 3000 WAH for hooded wraparound throughout the cartoning process and encases. Syntegon Technology also suggested ables operators to quickly clean and adjust the Elematic 3000 WAH XXL case packer the machine. The Elematic Click System, to carton the 8 oz (225 g) and 23 oz (650 g) which is a standard feature on the Elematic stand-up bags of the Qi’a superfood break3001 series, allows for tool-free and reprofast cereal at the Wisconsin site. These ducible format changes. An audible clicking case packers are suitable for shelf- and noise indicates to operators when the parts retail-ready products that are transported, have successfully locked into place. This stored and displayed in large cases—such as eliminates the need for adjustments and corrugated display bins placed on end caps minimizes errors, while helping Nature’s of supermarket aisles. Path to reduce scheduled downtimes. For“The team proposed a case packing solumat changeovers can be performed in about tion that offers us high production speeds, eight minutes, depending on the grouping maximum flexibility and an improved user pattern. The machine also features an exterexperience. In doing so, they have helped us nal hotmelt granulate container and an HMI become more sustainable. We managed to intuitive control panel, which enables operreduce our need for corrugated case maators to program format selection, position, terial by up to 15%, which translated into speed, timing and glue position. substantial cost reductions as well as a significant contribution to our environFOR MORE INFORMATION, VISIT WWW.SYNTEGON.COM mental mission,” Mehrotra says. June 2020
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June 2020
DRY PROCESSING TECHNOLOGY
HYGIENIC BATCH MIXERS Gericke USA • www.gerickegroup.com Multiflux GMS mixers feature a proprietary, hygienic design as standard to promote fast, complete cleaning, ensure product purity, and minimize risk of batchto-batch cross-contamination. They have an oversized entry door that seals the entire front of the mixer during operation then fully opens with no tools to invite safe, easy access to the internals for a thorough cleaning of the mixing chamber. Suitable for gently mixing food, dairy, grain, nutrition and other products requiring sanitary processing. NON-CONTACT LEVEL SENSORS BinMaster • www.binmaster.com Custom-configured 80 GHz non-contact radar level sensors are available in three different types of housings, including aluminum and stainless steel materials available for food applications. Mounting straps are used for aiming the plastic-housed NCR-80 over a conveyor, pile or in a bin. June 2020
EQUIPMENT FOR ESSENTIAL BUSINESS Bunting Magnetics • www.bunting magnetics.com The company’s magnetic separation, metal detection and conveying equipment keeps essential businesses, such as food processing, operating smoothly. The equipment separates, detects and removes ferrous and nonferrous metal contaminants from foods, ranging from flour to meat to final packaged products. If any sort of metal contamination were to be present in food, equipment in the food processing line could be damaged and operations could be forced to shut down.
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FIELD
REPORTS
Thirsty for success Lord Hobo Brewing expands cooling system with the help of GF Piping, all while remaining operational
SEARCH FOR THE UPGRADE The brewery considered four methods of installation: welded/threaded steel and
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copper, solvent cemented and fused plastic, but ultimately chose a preinsulated plastic system joined with solvent cement. Irwin had attended a Master Brewers meeting, where he learned about the CoolFit ABS Plus from GF Piping Systems. “After learning more about the system at the actual seminar, I was sure which system we’d choose.” FOR MORE INFORMATION, VISIT WWW.GFPS.COM
June 2020
PHOTO COURTESY OF GF PIPING
B
oston-based Lord Hobo Brewing Co. was a cavernous 49,000-sq.-ft. warehouse five years ago. With the vision of owner Daniel Lanigan, the fully functioning brewery opened its doors in 2015 and produced 5,000 barrels the first year. While the team was aware of the important role of the cooling loop in the brewing process, the ambitious startup was purposely planned as an inexpensive short-term means of getting the brewery operational, according to John Irwin, Lord Hobo’s maintenance and facility manager. “The goal was to be up and running as quickly as possible,” he says. “So a small PVC glycol system was installed along with a 20-ton chiller. This allowed production of the first ales within a few Lord Hobo Brewing weeks after starting con- had to rapidly expand struction of the facility.” its cooling system After tripling in size after as its production just two years of business, ballooned. Lord Hobo was named in the June 1, 2017, edition of the Boston Herald as the fastest growing brewery in America. Because of this quick expansion, the PVC glycol cooling system became overtaxed. “With just a 300-gallon reservoir and small 3-inch trunk lines coming out to supply 15 tanks, it simply didn’t have the flow or the cooling capacity to keep up with the growth rate,” says Irwin.
FIELD
REPORTS After a day of training by the manufacturer, the crew installed 800 ft. of d225 (8”) and 250 ft. of d110 (4”) without interfering with brewery production. At the same time, a 200-ton chiller and a 3,000-gallon reservoir were installed (compared to the previous 300-gallon reservoir). The system conveys glycol at 28°F to maintain the tank farm fermentation process, which includes 44 vessels in 160BBL (24), 80BBL (12) and 10BBL (8). “The GF transition fittings we used to connect the Cool-Fit ABS Plus to some existing copper and threaded pipe areas were easy to use and connected smoothly and effectively. We made roughly 450 joints and ran almost 1250 ft. of pipe with hundreds of fittings. Maintenance on the system is next to nothing—just a daily walk through to visually check the lines. Temperature loss in the system is virtually nonexistent and the Cool-Fit pipe remains accessible but hidden,” Irwin says. The company’s main building houses beer production and a tasting room with more than 25 types of craft beer on tap. Cold storage and office space are across the street in a 14,000-sq.-ft. structure. In the next two to four years, the Lord Hobo team plans to complete the tank farm of 11 rows, seven deep—77, 160 BBL vessels, and as many 10 BBL tanks as they can squeeze in. In anticipation of that, the new cooling system is already installed with valves in place ready for hookup. By the end of 2017, the brewery produced close to 20,000 barrels a year and in its third year reached 32,000 barrels, a 420% growth rate. In 2019, the Lord Hobo team stepped up that output to more than 50,000 barrels. June 2020
Lord Hobo’s mantra—“To bring the New England craft beer experience to thirsty fans everywhere—Lords and Hobos alike—we all deserve to drink like royalty”—was fulfilled uninterrupted during the new cooling system expansion. THE COOL-FIT SYSTEM WAS EASY TO CONNECT AND REQUIRES ALMOST ZERO MAINTENANCE.
Irwin is proud that they never lost a day of production doing the install. “We never interfered with operation or disrupted production,” he says. “We wouldn’t have been able to do that with steel pipe because we’d have had sparks flying everywhere.”
FOOD ENGINEERING
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ENGINEERING
R+D
WAYNE LABS SENIOR TECHNICAL EDITOR
Heat exchangers get better with age Take what you know works and research new capabilities
U
nlike an infinitely popular PC operating system that gets more complex as it ages—with layers upon layers of spaghetti code requiring ever increasing processing power to keep up—some things actually get better with age as creative engineering improves performance, decreases energy usage ARNOLD KLEIJN, and makes a device more effiproduct development cient and better able to handle director at HRS Heat a new range of food or beverage Exchangers products. I’m thinking heat exchangers—not software! With a slew of patents to its name, HRS Heat Exchangers has been around since 1981 and has been making thermal products for a number of industries, including food, pharma, chemicals, water and waste-to-energy, etc. The manufacturer makes several types of heat exchangers, such as shell and tube, brazed plate, corrugated tube, scraped surface and more. In fact, the R Series has been covered in FE going back to 2014. The R Series is a helical, scraped-surface heat exchanger, which has seen a number of food and beverage applications over the years and has evolved through engineering improvements in single-, three- and six-tube versions. There also is a heavy duty model (RHD Series), recently developed to handle viscous applications, such as chocolate-based dressings, ketchup, cheese sauces, dairy and vegetable concentrates—for example, condensed milk, tomato paste, nut butters or honey. What’s novel about adapting the heat exchanger to new applications? Here are a couple of examples.
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The R Series can be run in reverse to improve product recovery, which has proved a success with high-cost products. The company has successful applications with chocolate tempering, and the R Series has been installed as crystallizers in an environmental ZLD (zero liquid discharge) application. I spoke with Arnold Kleijn, product development director at HRS Heat Exchangers, to get a few more details on what’s in the works. FE: When HRS got started nearly 40 years ago, what were the first types of heat exchangers you made? Arnold Kleijn: We started the busi-
ness in the HVAC Industry using PHE’s (plate heat exchangers). FE: You obviously saw a great need for special types of heat exchangers in food and beverage applications? What were your first solutions? Kleijn: When we acquired a business in
Spain we started out with our corrugated shell-and-tube type heat exchangers with three main types: double-tube, triple-tube and multi-tube. FE: The R Series is a scraped surface, helical rotating device. How is this different from a helical coil heat exchanger?
June 2020
ENGINEERING
R+D
The R Series scraped surface heat exchanger uses a reversible helical screw to recover product without damaging the goods.
Kleijn: It bears no resemblance to a helical
coil heat exchanger; they are normally double-tube or tube-in-tube type and are not scraped surface. The helix is a screw conveyor welded to the scraper bar to reduce pressure drop and assist with mixing of the product for better heat transfer. It can reach velocities of up to 300 rpm, resulting in very high levels of shear and increasing the heat transfer rate. FE: How is the R Series different from other rotating heat exchangers? Kleijn: There are various reasons; here is a
quick list: • Multi-tube option (up to six tubes in a single heat exchanger) • Multi-pass option • The helical screw • Longitudinal baffles (improves heat transfer) • Removable tubes • Heavy-duty version
P H O T O S C O U R T E S Y O F H R S H E AT E X C H A N G E R S
FE: You mentioned the R Series can be run in reverse for cleanouts. Why do this? Is HRS the only one to do this? Kleijn: To enhance product recovery and min-
imize waste and save costs, as far as we know we are the only company to offer this. FE: What were the design considerations for the heavy-duty RHD Series? Kleijn: We did a trial on nut butter with
the standard R Series, and the unit wasn’t strong enough, so we redesigned the unit June 2020
to cope with the arduous duty, which resulted in making the following design changes: • Stronger gearbox (metal parts not plastic) • Larger diameter scraper bar • Extra scraper supports • Extra motor support FE: Could you tell us about the new developments to the R and RHD Series since 2018? Kleijn: The multi-pass option for the R3; the
RMP multi-pass arrangement links each of the three tubes in series: product enters through one tube, passes down the next and then moves back up the third. The use of longitudinal baffles in the outer shell achieves a true counter-current flow to improve heat exchange efficiency. FOOD ENGINEERING
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ENGINEERING R+D FE: What are some applications for the R and RHD Series? Kleijn: We wanted to handle some tough
applications that always presented flow problems, for example, heating and cooling viscous and fouling foods, such as nut butters, honey, meat pastes, jams and diced fruits. In addition, these heat exchangers work in chocolate tempering and pet food applications. FE: You also have a patented reciprocating model called Unicus. Describe its operation and intended applications. Kleijn: The Unicus design is based on a
exchange surface. This keeps heat transfer high and reduces downtime. In addition, the scraping movements introduce turbulence in the fluid increasing levels of heat transfer. This design makes the Unicus Series the ideal heat exchanger for applications where fouling or low heat transfer is a limiting factor. The Unicus Series can be applied in industrial and hygienic applications. The gentle movement of the scrapers allows the system to be used with delicate products, such as whole fruit or vegetable pieces, without destroying the product integrity.
traditional shell-and-tube heat exchanger with scraping elements inside each FE: Which came first: R Series or Unicus? tube. The reciprocating movement of the Kleijn: The Unicus. scrapers mixes the fluid FOR MORE INFORMATION, VISIT WWW.HRS-HEATEXCHANGERS.COM/US while cleaning the heat
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SPECIAL ADVERTISING SECTION
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foodengineeringmag.com/webinars
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Further information on these companies can be found in the 2019-2020 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.
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N TS & BOL S
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19%
Percentage of people in the food and beverage industry who say their companies TEMPORARILY CLOSED TO KEEP EMPLOYEES HEALTHY
62%
Percentage of people in the food and beverage industry WORRIED ABOUT SUPPLY CHAIN INTERRUPTIONS.
SOURCE: FOOD AND BE VER AGE INDUSTRY SURVE YS ON THE PANDEMIC, CLE AR SE AS RESE ARCH
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“Without question, sustainability will remain a primary consideration in the design and development of pet food packaging moving forward.” —Bill Kuecker, vice president of marketing, Mondi Consumer Packaging
BLOCKCHAIN IN AGRICULTURE MARKET EXPECTED TO RISE 41% The global market for blockchain in agriculture is expected to jump 41% CAGR over the five years ending in 2029, reaching $2.06 billion, according to a Future Market Insights report. Increasing cases of food contamination and food scams in agricultural are driving growth in transparent supply chain methods. Platforms for product traceability, monitoring and visibility are expected to dominate the market. COVID-19 pandemic adds an unknown element. Stay-at-home orders that resulted in a sudden increase in the blockchain consumer footprints on the agricultural sector culminated in logistical challenges and then a normal sales drop.
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June 2020
IMAGES: GET T Y IMAGES
SURVEY: BUSINESS WILL BE OFF TRACK ABOUT 7 MONTHS Food and beverage manufacturers say their companies will need an average of seven months for business to get back on track, according to a series of industry surveys. Just under half of current and/or planned business has been delayed or cancelled, according to the survey results from Clear Seas Research, a BNP Media company. About 30% report their companies laid off employees, while about 20% say they expect to hire new employees and/or rehire laid off employees in the coming months. Half say that their companies could qualify for a small business stimulus loan, and about 18% have been approved for one, though a large portion did not receive the money right away. A quarter applied and were waiting to hear back. Download the full report for free at https:// www.clearseasresearch. com/fbreport
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Join us in July with leading experts as we navigate the sometimes tumultuous world of legal cannabis, food, and beverage.
Keynote: Learnings from a Journey into Canna-Beverages
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Eric Schnell, Founder, BeyondBrands & Co-Founder, mood33
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| contents |
| volume 3, issue 2 • june 2020 |
cannabis products
24
| features |
CPX20 6
Cannabis Products Exchange Our inaugural Cannabis Products Exchange event will take place in Denver on July 30 to 31.
law 8
Seeking federal compliance In the absence of federal movement on using CBD in foods and beverages, cannabis companies tackle cGMPs.
business | departments | 5 editor’s note 22 new products 28 packaging 34 ingredients 40 equipment 44 ad index
11 Establishing production Companies have multiple questions to address when establishing production dynamics for manufacturing cannabis-infused products.
product development 14 Beverages with a boost Cannabis beverage brands are incorporating fruit juices, botanicals, and other health-based ingredients. 17 Medical necessities The market for medical cannabis foods and beverages is poised for significant growth.
packaging
14
24 Engaging today’s cannabis consumer Distinct consumer populations are emerging, illustrating diverse future directions for the industry.
30
ingredients 30 Capitalizing on encapsulation Applying encapsulation and emulsification methods increases cannabinoid bioavailability and stability.
equipment
48
36 Advancing through automation Automating select aspects of cannabis-infused food and beverage production can bring strategic advantages. 42 Sanitizing for safe edibles Cannabis food and beverage manufacturers need to follow GMPs for equipment cleaning and sanitization.
cover images courtesy of Calexo, Wana Brands, and Rebel Coast Winery cannabis products | june 2020 3
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| editor’s note |
cannabis products
editorial and sales offices 155 N. Pfingsten Road, Suite 205 Deerfield, IL 60106 847-405-4100 editorial Douglas J. Peckenpaugh Group Editorial Director peckenpaughd@bnpmedia.com Alyse Thompson Managing Editor thompsona@bnpmedia.com production & art Nann Barkiewicz Production Manager barkiewiczn@bnpmedia.com MaTT Britcher Art Director britcherm@bnpmedia.com publishers Mike Leonard Prepared Foods leonardm@bnpmedia.com Mark Tisdale Food Engineering tisdalem@bnpmedia.com Chris Luke Food Safety Strategies lukec@bnpmedia.com sales Eileen Casey (630) 441-6293 caseye@bnpmedia.com Marci Cunningham (941) 321-1255 cunninghamm@bnpmedia.com Ray Ginsberg (856) 802-1343 ginsbergr@bnpmedia.com Kim Hansen (248) 786-1233 hansenk@bnpmedia.com Sam Wilson (847) 405-4075 wilsons@bnpmedia.com Pam Mazurk (847) 247-0018 mazurkp@bnpmedia.com Steve Rooney (201) 412-7060 rooneys@bnpmedia.com Wayne Wiggins (415) 387-7784 wwiggins@wigginscompany.com
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CANNABIS AND CRISIS RESISTANCE Douglas J. Peckenpaugh
W
hat a difference a few months makes. Since our last issue in March, the world has been turned upside-down due to the COVID-19 pandemic. Our global perspective has forever shifted—including our perspectives on cannabis. As individual U.S. states took the necessary steps toward shutting down or providing guidance for public infrastructure, commerce, and day-to-day life, those states almost invariably designated the cannabis industry as “essential,” allowing businesses to stay open. This shows particularly strong positioning for the industry, with great support at the state level. Cannabis businesses will also hopefully see some much-needed federal support in the near future. On May 12, House Speaker Nancy Pelosi unveiled a $3 trillion+ coronavirus aid package—the Health and Economic Recovery Omnibus Emergency Solutions (HEROES) Act, a large bill containing emergency economic appropriations. Thankfully, the initial draft of the HEROES Act includes the Secure and Fair Enforcement (SAFE) Banking Act, a measure that would ensure access to financial services for cannabis-related businesses and service providers. This financial support and protection is necessary and long overdue, and deserves strong bipartisan support. As I’ve been communicating with suppliers and product developers over the past several weeks, the feedback regarding any negative impact caused by COVID-19 has been mostly encouraging. While some fallout from the pandemic is inevitable, reports from the field have cited minimal impact to date. As essential businesses, cannabis is soldiering on, and we’re continually covering all developing industry news on our online home at www.cannabisproductsmagazine.com. As of press time in May, we are still planning to hold our inaugural Cannabis Products Exchange event—dubbed “CPX20” and now taking place July 30–31 in Denver—focused on product development and manufacturing for cannabis-infused foods and beverages. Our events team has gone to great lengths to ensure that the live event experience takes into account all of the necessary precautions for a safe and productive event. CPX20 is the only cannabis industry event completely focused on product development, and will provide unique opportunities for a comprehensive education program, trade show, networking, and more, all with the goal of establishing strategic opportunities for collaboration to drive this essential, resilient—and forward-thinking—industry forward. I hope to see you there.
CPX20
CANNABIS PRODUCTS EXCHANGE
THE NEW FRONTIER OF LEGAL CANNABIS EDIBLES & BEVERAGES
Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media.
cannabis products | june 2020 5
JULY 30-31 | HILTON DENVER CITY CENTER | DENVER, COLORADO
WELCOME TO THE NEW FRONTIER
CPX20
CANNABIS PRODUCTS EXCHANGE
THE NEW FRONTIER OF LEGAL CANNABIS EDIBLES & BEVERAGES
CPX20 will foster significant interaction between suppliers and producers to help shape a sustainable future in cannabis food and beverage development. CPX20: Cannabis Products Exchange will take place July 30 to 31 at the Hilton Denver City Center in Denver, the global epicenter of the legal cannabis industry. CPX is different than any other cannabis event in existence today. We are 100 percent focused on product development. We’re striving to connect the dots between companies that are developing and processing cannabis foods and beverages and the industry’s supply-chain, which is striving to bring the right ingredients, equipment, packaging, logistics, branding and more to fuel sustainable, science-based growth. When an industry is this new, finding just what you need to grow can prove challenging, and CPX is here to help streamline the process. Addressing the challenges of the legal cannabis food and beverage industry is a core mission of Cannabis Products magazine and our CPX event. Our gathering in Denver will provide a highly unique and strategic forum to develop collaborative solutions, with suppliers to the industry and cannabis-infused product developers working together in an intimate environment to advance key areas related to product quality, safety, consistency, efficacy, and more. We’ve invited top leadership from across the industry to share their insights, and together, we can take this exciting industry to the next level.
6 cannabis products | June 2020
CPX20 Agenda Highlights THURSDAY, JULY 30 8:00-9:00 am Registration, Breakfast, Exhibits 9:00-10:00 am Keynote Session: Learnings from a Journey into Canna-Beverages Eric Schnell, Founder, Beyond Brands; Co-Founder, mood33 10:00-10:30 am Refreshment Break in the Exhibit Hall 10:30-11:15 am Strategies for Success in the Cannabis Edibles Industry Jesse Burns, Marketing Director, Sweet Grass Kitchen 11:15-12:00 pm The Cannabis Opportunity: Understanding Consumer Need States and Preferences Carl Edstrom, Sr. VP & Principal, Survey Solutions, IRI Jessica Lukas, Sr. VP, Commercial Development, BDS Analytics 12:00-1:30 pm Networking Luncheon in Exhibit Hall 1:30-2:15 pm Establishing Benchmarks for Cannabis Food & Beverage Success Christian Sweeney, Vice President of Science and Technology Matt Hepfinger, Vice President of Commercialization, Cannabistry Labs 2:15-3:00 pm Understanding Cannabis Ingredient Processing Dynamics Matthew Anderson, CEO, Vanguard Scientific Systems 3:00-3:30 pm Refreshment Break in the Exhibit Hall 3:30-4:15 pm What Can Be Carried Over from Traditional CPG to Cannabis? Tom Newmaster, Partner, FORCEpkg Sponsored By:
FRIDAY, JULY 31
8:00-9:00 am Registration, Breakfast, Exhibits 9:00-9:45 am Keynote Presentation: A Roadmap to Legal Cannabis Food & Beverage Product Development Mike Hennesy, Director of Innovation, Wana Brands 9:45-10:30 am Creating Unified Cannabis Food & Beverage Safety Production Protocols Lezli Engelking, Founder, FOCUS: The International Cannabis Health & Safety Organization
Sponsored By:
10:30-11:30 am Networking in Exhibit Hall
11:30am-12:15pm Legal Insights into the Cannabis Edibles & Beverage Industry Steve Schain, Esq., Senior Attorney, Hoban Law Group Justin J. Prochnow, Shareholder, Greenberg Traurig 12:15 pm Conference Adjourns
CPX20
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THE NEW FRONTIER OF LEGAL CANNABIS EDIBLES & BEVERAGES
JULY 30-31, 2020
HILTON DENVER CITY CENTER, DENVER, COLORADO
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cannabis products | June 2020 7
| law |
SEEKING
FEDERAL COMPLIANCE In the absence of federal movement on using CBD in foods and beverages, cannabis companies tackle cGMPs.
T By Douglas J. Peckenpaugh Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media. 8 cannabis products | june 2020
he 2018 Farm Bill set the U.S. on a path toward significantly greater national exposure to cannabidiol (CBD) when it authorized cultivation of varieties of cannabis (or “industrial hemp”) bred to have minimal concentrations of tetrahydrocannabinol (THC). However, despite some specific funding earmarked for FDA and its work with CBD, we have seen little federal movement toward establishing a pathway for using CBD in foods and beverages. But that hasn’t stopped some companies from establishing a strong framework for development of cannabis-infused foods and beverages, including work related to compliance with FDA’s current good manufacturing practices (cGMPs).
A KNOWN FRAMEWORK As noted by FDA: “Following current good manufacturing practices (cGMPs) helps to ensure the safety of food. cGMP regulations generally address matters including appropriate personal hygienic practices, design and construction of a food plant and maintenance of plant grounds, plant equipment, sanitary operations, facility sanitation, and production and process controls during the production of food.” A comprehensive overview of cGMPs, as well as the rule for “Hazard Analysis and Risk Based Preventive Controls for Human Food,” is published in 21 CFR Part 117, as well as in 21 CFR Part 111 for dietary supplements. Establishing FDA certifications for cGMPs is a good first step for companies
| law | CANNABIS COMPANIES WITH DOCUMENTED, REGISTERED GMP CERTIFICATION INCLUDE:
COMPANY Charlotte’s Web Hemp Depo Mile High Labs
PRODUCTS Hemp oils; CBD Hemp seeds/oils; CBD CBD and hemp extracts
REGISTRATION NSF Dietary Supplements GMP NSF Dietary Supplements GMP SGS GMP
CANNABIS COMPANIES WITH GMP AUDITS INCLUDE:
COMPANY
PRODUCTS
Bluebird Botanicals
Hemp extracts
Commonwealth Extracts Stillwater Brands
Hemp oils; CBD products THC- and CBD-infused foods and beverages
working in cannabis as part of establishing key aspects of a food safety program. “With the 2018 U.S. Farm Bill’s passage federally legalizing hemp production and interstate transport, consumer products containing hemp-derived compounds such as cannabidiol (CBD) have expanded, and the variety and number of CBD health, nutrition, and food products are readily accessible through a number of retail and online outlets has exploded,” says Steve Schain, Esq., senior attorney, Hoban Law Group, with offices in Philadelphia and Cherry Hill, NJ. Establishing cGMPs lays the groundwork for the requisite level of corporate transparency that U.S. consumers need in order to fully embrace CBD-infused foods and beverages. This is a new area of product development, and people need assurances that the products meet federally structured rubrics for safety. “As the global hemp industry matures, companies scaling for future growth and looking to remain competitive and align with international industry standards are embracing cGMP regulations, helping ensure food product quality, safety, and efficacy through addressing all production process aspects,” says Schain.
NEW TERRITORY For many of the companies working in cannabis-infused foods and beverages, establishing cGMPs is new territory. These guidelines are not specific to CBD or cannabis. They simply create a structure for the safe development and manufacture of cannabis-infused foods and beverages in general. “Companies manufacturing prod-
ucts containing CBD or hemp must comply with the cGMPs in 21 CFR Part 117 for food and beverages or 21 CFR Part 111 for dietary supplements,” says Justin J. Prochnow, shareholder, Greenberg Traurig, LLP, Denver. “Many companies in the CBD and hemp industry are not coming from a position of previous compliance, so this is new for them.” He notes that NSF International has started inspecting cannabis companies for compliance. While we have not seen any movement from FDA in the area of establishing a structure for use of cannabis-derived compounds like CBD in foods and beverages, FDA has made a point of issuing warnings to companies making health and medical claims. “Several companies manufacturing products with CBD and hemp have received warning letters from the FDA due to claims related to the treatment or prevention of the coronavirus,” says Prochnow. “In those letters, the FDA was only focused on the coronavirus, and didn’t even raise the issue of whether CBD or hemp is permissible in a dietary supplement or a food or beverage.”
REGISTRATION Eurofins GMP audit/GMP for Dietary Supplements audit AIB International GMP audit Eurofins Dietary Supplements GMP audit We have seen some action taken at the state level, though, regarding CBD-containing products. “Virginia recently passed legislation making it legal to sell products with CBD and hemp, and several states have issued recent regulations regarding the labeling of products with CBD and hemp, such as Alaska and Vermont, which goes into effect July 1.” These labeling rules often seek to provide more transparency, clarity, and assurance for consumers. For instance, in Vermont, labeling for CBD products will need to include the name and address of the manufacturer, an ingredient statement, manufacturing and expiration dates, a process lot number, and verified levels of cannabinoids present in the product traceable to a certificate of analysis. Companies that take steps toward establishing a strong regulatory awareness will likely find themselves better prepared to quickly enter the federal marketplace once FDA provides guidelines for use of non-psychoactive cannabis-derived compounds in foods and beverages.
L EG A L C A NN A BIS INSIGH T S During the inaugural Cannabis Products Exchange (CPX), taking place July 30–31, Justin J. Prochnow, shareholder, Greenberg Traurig, and Steve Schain, senior attorney, Hoban Law Group, will participate on a panel discussion on the topic of “Legal Insights into the Cannabis Edibles & Beverages Industry.” In the absence of unified federal clarity regarding several aspects of legal cannabis food and beverage product development, processing, and sale, companies working in this industry—or seeking to enter it—need insight into the legal hurdles and challenges they currently face. Topics of discussion will include: • Current federal perspectives on banking • Cannabis business taxation protocol and requirements • Using CBD in foods and beverages • Brand and trademark protection for cannabis foods and beverages • Federal pathways toward a medical and recreational cannabis regulatory framework
cannabis products | june 2020 9
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MANUFACTURING
| business |
ESTABLISHING
PRODUCTION Companies have multiple questions to address when
establishing production dynamics for manufacturing cannabis-infused foods or beverages.
C
ompanies looking to establish or fine-tune the parameters required for production of cannabis-infused foods and beverages need to take a hard look at their supply chain. And while the supply chain for this industry continues to grow more sophisticated, some aspects of manufacturing cannabis-infused consumables require special consideration in order to establish a platform for ongoing success in this increasingly competitive market.
ANALYZING INGREDIENTS “When it comes to a producer setting up a cannabinoid ingredient supply chain,
the first thing you would want to establish is that your incoming raw materials have been tested for quality and safety purposes,” says Mike Schmitt, regulatory manager, SōRSE Technology, Seattle. He notes that it’s important to ensure the ingredient supplier has a structured and comprehensive food safety plan to make sure that during their process they meet operational specifications and maintain food safety. “Once the production process is completed, the finished product—the emulsion—should go through final testing to meet finished quality and safety specifications.” Schmitt also notes that some state departments of agriculture have approved
By Douglas J. Peckenpaugh Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media. cannabis products | june 2020 11
| business | hemp cultivation and processing programs. In such states, the ingredient supplier should be licensed with the department of agriculture, he says. “For those states that don’t currently have such a program, ask to see if the extractor has a third-party audit that conforms to the Global Food Safety Initiative (GFSI) standard.” Transparency in today’s fast-emerging cannabis industry is vital, says Schmitt. “As a business owner, you have to define what transparency means to you and to your consumer. Without defining that term up front, you will not be able to deliver as you feel fit. In order to meet the level of transparency you want to achieve, be sure to have a good conversations with your suppliers and make sure your questions get answered.” He points to certain expected standards of transparency in the food industry, such as having third-party audit documentation, product data sheets with specifications, Nutrition Facts information, and ingredient and allergen statements. “We are somewhat unique in our ability to not only have a team of scientists who can customize an emulsion for you, but we can also help with the application of the emulsion to your specific product,” says Schmitt. He notes that this includes both developing a protocept—a conceptual prototype using your ingredients and/or your formulation—and guidance regarding how to add cannabinoid ingredients to the customer’s process. “For example, in the beverage world, one can mix all the ingredients into a giant holding tank before processing, or you can add your water to a concentrated slurry with inline mixing. We can help in both of those cases.” Quality, consistency, and transparency are the top considerations when searching for the right supplier, suggests Jake Black, Ph.D., CEO, Treehouse, Longmont, CO. “There are many key players in the cannabinoid ingredient supply chain, starting with farmers growing cannabis and extending all the way to retailers. In between these points are hemp processors, extractors, testing labs, formulators, and more.” If any one of these links in the chain skimps on quality, the entire supply chain can end up compromised, potentially leading to major ramifications or a product recall, he says. “Alongside this, consistency is obviously key. If your end consumer cannot be guaranteed that their product will always be safe and always have the same 12 cannabis products | june 2020
MANUFACTURING effects, you will rapidly lose credibility.” Transparency is critical for cannabinoid ingredients, says Black, because the lack of clear, standardized, federal regulation means the industry must sometimes self-regulate. “If any portion of the supply chain is not transparent with everything they do, that is a huge red flag. A lack of transparency seriously puts into question someone’s ability to consistently deliver quality products or services,” he says. Black suggests that manufacturers of cannabis-infused foods and beverages get familiar with reading and understanding certificates of analysis (COAs). “Because of the lack of clear regulation on cannabinoid-containing products, there are varying—or nonexistent—standards for many products. That means all ingredients should be tested thoroughly, batch by batch, for a variety of potential contaminants, such as pesticides, heavy metals, solvents, and microbials. Additionally, tests for cannabinoid potency and THC compliance are key.” An ability to read and understand COAs helps individuals compare ingredients from different suppliers—and to help ensure safety and quality. “At Treehouse, we strive to provide as much support as possible to all our customers,” says Black. “We make our team of Ph.D. chemists available for phone calls so they can share their knowledge on cannabinoid ingredients. Frequently, they discuss product quality, safety, our processing technologies, and new scientific developments with cannabinoids. We love brainstorming with customers to see how they can leverage our scientific expertise to differentiate their products in a crowded marketplace.”
EQUIPMENT INSIGHTS Vetting equipment suppliers likewise requires some savvy analysis, notes David M. Miles, executive vice-president, MTI BioScience, Raleigh, NC. A key question to consider is whether or not the equipment supplier has the requisite level of experience to foster growth. He suggests asking the following questions when vetting suppliers: • Are they experts in their field? • Do they understand the requirements of the cannabis ingredients? • Are they legally set up to work in the cannabis field, including banking? • State cannabis laws are not standardized. Do they understand what can be
done in different states? • Can they support you in the long term? “We customize our UHT/HTST/aseptic processing equipment for our clients’ needs,” says Miles. “For example, some products in the cannabis industry are extremely expensive, such as CBD extract. For these types of products, we modified our designs for strictly minimizing any waste, and strictly controlling portions and filling.” Also, Miles notes that many new companies entering cannabis-infused product manufacturing do not have experience running formal processing equipment. “To address this, we simplify operation through custom automation,” he says. “We provide extensive support for our customers’ product development process,” says Miles. “Much of the HTST/UHT/ aseptic processing equipment we provide is used specifically for R&D. Many companies developing cannabis beverages do not have much food product development experience. They don’t understand the affects thermal processes have on products. We specialize in thermal processing and can help them develop and optimize thermal processes to maximize their product quality and functionality.” Miles notes that his company has seen a number of common mistakes to avoid in this potentially lucrative industry, including: • Using incorrectly specified equipment, resulting in expensive re-work solutions • Lack of logical, “flow-through” design of the facility, making production inefficient and difficult • Hiring friends rather than qualified people and staff to design and run the facility, resulting in facilities not meeting required standards and regulations • Not having plans that enable them to satisfy potential FDA, sanitary, and/or other requirements “Be careful who you partner with,” suggests Miles. “There are a lot of companies that are looking to make the fast buck and skimp on quality. Looking for the cheapest solutions will result in the lowest-quality solutions with little or no support. Look for companies with a long, successful history of partnering with clients and providing long-term solutions. It will be less expensive, and more successful in the long run.”
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| product development |
BEVERAGES
BEVERAGES WITH A BOOST Cannabis-infused beverage brands are
incorporating fruit juices, botanicals, and other health-based ingredients into the mix. courtesy of Calexo
By Alyse Thompson Alyse Thompson is managing editor of Cannabis Products. 14 cannabis products | june 2020
T
oday’s cannabis industry is increasingly appealing to a wider range of consumer demographics seeking to enhance their lives through plantbased benefits. While medical cannabis consumers are authorized by their states to use infused foods and beverages to alleviate health concerns, others are turning to recreational cannabis-infused products for
relief from pain, anxiety, and other issues on a less-formal basis. Some consumers are using cannabis-infused products as part of lifestyle centered on balance and wellness. Though they require extra manufacturing considerations, infused beverages, particularly those made with fruit juices, botanicals, and other ingredients with “healthy” benefits, can easily fit into such a lifestyle.
| product development | BOTANICALLY APPEALING Jonathan Eppers, founder and CEO, VYBES, Santa Monica, CA, says he believes beverages are the best format for getting cannabidiol (CBD) into the body. “As a society, the way we live our lives, the distractions, the noise, and—at times—the feeling of being overwhelmed, really take a toll on the mind and body,” says Eppers. “I started VYBES to address what’s becoming a more-urgent health need for people: everyday stress and anxiety. Hemp CBD has the potential to help a lot of people.” Launched in 2018, VYBES is a line of infused beverages made with hemp-derived CBD, fruit juices, herbs, and other botanicals. Each 14-oz. bottle contains 25 mg of CBD and 3–12 grams of sugar. Available varieties include Blackberry Hibiscus, Blueberry Mint, Honeycrisp Apple Basil, Peach Ginger, and Strawberry Lavender. VYBES also offers a Burning Mandarin variety, which includes tangerine juice, carrot juice, turmeric, green tea, and cayenne pepper. “In thinking about beverages, it was very important to me that not only does VYBES address a health need, but an occasion need, meaning we want people to consume VYBES throughout the day,” Eppers says. “By making our beverages taste great, it can enhance the desire to consume one of our beverages while also gaining the functional benefits of CBD.”
FRESH PERSPECTIVES Ian Colon, co-founder and chief marketing officer, Calexo, Los Angeles, notes that its consumers often seek the beverage brand, infused with tetrahydrocannabinol (THC), in order to relax, in addition to improving their overall wellness. In addition to THC, Calexo formulates the infused beverages with fruit juices and botanical ingredients. The interesting flavors that these ingredients add to the beverage are alternatingly designed to complement the cannabis flavor of the drink, or diminish it. “On top of having the physical effects to the body and mind that people expect with cannabis, it also has a distinct flavor,” says Colon. “While some of us love this
courtesy of VYBES taste, others don’t. We utilized the earthy flavor of cannabis with our fruit juices to enhance the overall flavor and produce a profile both original and captivating.” Launched in March, Calexo is initially available in two varieties: Citrus Rose and Cucumber Citrón. Each 22-oz. bottle contains 10 mg of nanoemulsified THC. “Our first two flavors were inspired by our love of both the taste and the simple and distinct visual style of the herbal liqueur-based cocktails popularized in early 1900s Europe,” Colon says. “With that motivation, we looked to celebrate the rich flavors of our home in California through its famous bright and crisp citrus.”
HEALTH-FORWARD FORMULATIONS Since the passage of the 2018 Farm Bill opened the door for greater acceptance of hemp, food and beverage manufacturers have begun adding hemp-based ingredients to their products, and not just for its association with CBD. Other
courtesy of Evo Hemp
portions of the hemp plant can contribute essential fatty acids and high protein content. Evo Hemp, Boulder, CO, offers hemp protein bars, as well as hemp seeds, hemp seed oil, and hemp seed protein—all ingredients deemed generally recognized as safe (GRAS) by the FDA. The company recently partnered with Honeydrop Lemonade to introduce a line of cold-pressed lemonades featuring hemp extract and other health-based ingredients. “Hemp extract can be a great addition in food and beverage products, as it helps balance one’s endocannabinoid system,” says Jourdan Samel, co-founder, Evo Hemp. The line features four varieties: Relax (Lemon and Hemp), Revive (Matcha and Hemp), Rehab (Turmeric, Pepper, and Hemp), and Reset (Charcoal, Cayenne, and Hemp). Each 10-oz. bottle includes 20 mg of hemp extract. “We wanted to provide our customers with a number of options so they could feel comfortable drinking our products anytime throughout the day without having any negative side effects,” Samel says. “Ultimately, this has helped increase brand recognition for both Honeydrop and Evo Hemp. We’ve seen the Honeydrop beverages flying off the shelf and expect this growth to continue.” Though consumers may turn to beverages as an easy and portable method to deliver CBD, THC, or hemp extract, incorporating fruit juices, botanicals and other healthy ingredients can help consumers pursue a wellness-based lifestyle. These cumulative benefits will likely help drive this popular category of cannabis products forward. cannabis products | june 2020 15
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MEDICAL
| product development |
MEDICAL
NECESSITIES The market for medical cannabis foods and beverages is poised for significant growth.
C
harlotte Figi was a revolutionary figure in medical cannabis. Born with Dravet syndrome, a rare form of epilepsy, she suffered from seizures every 30 minutes—until her parents met with the Stanley brothers, siblings in Colorado who were breeding a medical cannabis strain with high levels of cannabidiol (CBD). Charlotte was their first patient. After she started treatment, her seizures significantly
dropped off—and then stopped—transforming her life. The Stanley brothers honored their first patient by naming their company, Charlotte’s Web, after her. Sadly, Charlotte succumbed to her syndrome in April. But Charlotte will forever serve as inspiration for the significant health, wellness, and medical potential of cannabis. “She made me realize that it would not just be a medical failing, but a moral fail-
By Douglas J. Peckenpaugh Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media. cannabis products | june 2020 17
| product development |
MEDICAL courtesy of GW Pharmaceuticals Epidiolex
ing if this medicine was somehow withheld from people,” said Dr. Sanjay Gupta in his tribute to Charlotte after she passed. In 2013, the noted neurosurgeon reversed his perspective on medical cannabis after hearing her story. For Charlotte and countless others dealing with epilepsy, cancer, Crohn’s disease, chronic pain, multiple sclerosis, Tourette’s syndrome, Parkinson’s disease, and many more syndromes, diseases, and conditions, cannabis is essential medicine. And the market for cannabis-infused foods and beverages shows significant potential for growth.
AN EMERGING MARKET In April, BDSA (formerly BDS Analytics) reported that 2019 legal cannabis sales grew by 46 percent to $14.8 billion, the industry’s highest annual rate of growth to date. BDSA noted that part of this strong growth was due to medical programs in U.S. states that reported higher-than-expected sales in 2019, boosting overall U.S. growth. But while medical cannabis research has likewise made significant strides over the past few years, this field is still in its infancy. “The medical cannabis market is in its nascent stage in numerous countries,” says Wayne Nasby, COO, Tikva, Los Angeles. “The market is estimated to possess high growth potential due to increasing legalization demand. Research on cannabis’s potential for medical use is on an upsurge. Many companies in the U.S. will further drive investigational research on medical cannabis, thus propelling industry growth.”
pain. Pain management is the largest application of medical cannabis, and research is aimed to reduce the overuse of opioids and combat the nationwide opioid addiction crisis.” According to the U.S. National Library of Medicine and Prohibition Partners, 564 clinical trials are currently ongoing that involve cannabis, says Maribeth O’Connor, vice president, medical applications, SõRSE Technology, Seattle. “Of these 564 studies, 343 are located in the U.S., 106 in Europe, 49 in Canada, and 35 in the Middle East.” She notes that the amount of research has exploded over the past couple of years related to treating depression, can-
“Many companies in the U.S. will further drive investigational research on medical cannabis, thus propelling industry growth”
seizure frequency from baseline by 30 to 40 percent in late-stage trials for patients with two rare forms of childhood-onset epilepsy, says Kristina Susser, senior vice president, medical group, SõRSE Technology. “Today, GW Pharmaceuticals is looking to expand Epidiolex’s label, and is working on new cannabinoid-based therapies for indications such as spasticity associated with multiple sclerosis and autism spectrum disorder.” In April, GW Pharmaceuticals announced that the DEA has descheduled Epidiolex so that is no longer a controlled substance. Following FDA approval in 2018, Epidiolex was initially placed in Schedule V of the Controlled Substances Act (CSA), meaning that it has a very low potential for abuse and has a currently accepted medical use in treatment. Descheduling the CBD-infused medicine removes all federal controlled-substance restrictions for Epidiolex. This demonstrates a strong federal perspective on the medical potential of CBD-based treatments.
FORMULATION INSIGHTS As the cannabis industry exponentially expands, so will medical research, seeking to find pathways to improve human life. “Research on cannabis’s potential for medicinal use is on the rise,” says Nasby. “Government organizations and private companies are undertaking several initiatives to explore medical cannabis for relieving 18 cannabis products | june 2020
cer, multiple sclerosis, amyotrophic lateral sclerosis (ALS, commonly known as Lou Gehrig’s disease), and more. “These studies have real potential to improve patients’ lives.” In 2018, FDA approved Epidiolex, a prescription oral solution from GW Pharmaceuticals made with CBD, which reduced
Today’s medical cannabis market is not without its challenges. “There are no uniform regulations, standardization, and/or quality standards to safeguard the patient’s health,” says Nasby. “Irregularities and non-uniformity of cannabis testing standards is a significant concern. Medical cannabis quality testing laws vary from state to state, with some requiring only THC and
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| product development | CBD reporting. Products are not subjected to rigorous consumer safety testing and, therefore, patients are left with the burden of finding and sourcing the best and safest medical cannabis themselves. Contaminated medical cannabis is particularly risky for medical cannabis patients with compromised immune systems.” Therefore, cannabis brands operating in the medical market must take extra steps to help ensure product safety and efficacy— and then clearly communicate those steps. “Food safety should be any food and beverage company’s primary consideration when developing products for vulnerable medical customers,” says O’Connor. “For example, our emulsion uses common, well-established food ingredients that are understood by the market. On the safety side, we test for pesticide residue, heavy metals, mycotoxin growth, and bacterial growth. On the quality side, we generate a certificate of analysis (COA), a lab report which verifies the chemical makeup of the emulsion, which details its cannabinoid, terpene, and contaminant profile.” Companies should have comprehensive
risk analysis and food safety plans that are common in the food industry, says Susser. “This would ensure that they meet top quality standards every step of the way.” She notes that SõRSE only uses pharmaceutical-grade materials when making formulations for vulnerable populations. Many current medical cannabis studies are honing in on the impact of cannabis on pain management, neurological/cognition/ sleep, obesity and diabetes, and addiction, says Susser. SõRSE Technology is collaborating with Pascal Biosciences on cancer research—and specifically the effect of cannabinoids on the major histocompatibility complex (MHC) receptor, which allows the immune system to identify a cancer cell, resulting in the immune system performing at a more-effective level. “CBD forces the MHC receptor to go back onto a cancer cell so the cancer cell can be identified,” she says. The next step of the research will investigate how and why that works. Susser notes that Pascal Biosciences has developed PAS-403, a mitosis inhibitor that blocks cell division. “The cannabinoid-based product is undergoing devel-
opment for the treatment of glioblastoma and brain metastases originating from other cancers. Pascal’s work is showing that CBD is helping your own immune system identify dangerous cells like cancer in your body, which then allows your T-cells to identify and attack those cancer cells. The CBD is reattaching an identifier mechanism that allows the T-cells to perform the way they were designed to.” The momentum behind the health, wellness, and medical potential of cannabis is increasing. “In the past two months, across the country we have seen a shift in the way the population and government officials view cannabis,” says Susser. “In mid-March, when many cities and states started enacting shelter-in-place orders, cannabis was deemed an essential business. This meant that both medical and recreational dispensaries would remain open and continue to serve their patients and customers. Because more cannabis users are trying edibles as opposed to buying flower, the outlook for medical cannabis food and beverage producers is highly positive.”
cannabis products | june 2020 21
| new products |
cannabis products
NEW PRODUCTS
Wana Quick Fast-Acting Gummies Company: Wana Brands Website: www.wanabrands.com Introduced: March 2020 Distribution: Colorado Product Snapshot: Wana Quick Fast-Acting Gummies have an onset of 5-15 mins and Delta-9-THC effects lasting up to three hours. This product line features an all-natural recipe, with no high fructose corn syrup. Each gummy offers 5 mg of THC, with 20 gummies per package. Wana Quick Fast-Acting Gummies harness TiME (Thermodynamic Individual Molecular Encapsulation), a new quick onset technology from Azuca. While traditional edibles convert Delta-9-THC in the digestive tract to 11-Hydroxy-THC, Wana Quick gummies feature individually encapsulated Delta-9-THC cannabinoids with greater bioavailability that work at the molecular level to bypass the liver and enter the bloodstream immediately. The encapsulation technology is paired with new flavors from Wana including: • CBD/THC 1:1 Strawberry Margarita: Features the sweet and citrusy flavors of a strawberry margarita with a hint of salt. Infused with CBD and THC terpene-enhanced distillate, this popular 1:1 ratio offers psychoactive effects while promoting relaxation and tranquility. • Sativa Peach Bellini: Features the juicy peach flavor of a sparkling peach Bellini. Infused with sativa terpene-enhanced distillate, which has been known to cause a more uplifting and motivating effect. • Indica Piña Colada: Features the rich and creamy pineapple and coconut flavors of a piña colada. Infused with indica terpene-enhanced distillate, which often results in a mellow, stress-relieving effect.
22 cannabis products | June 2020
| new products | THC-Infused Sparkling Wine Blends, Seltzers Company: Rebel Coast Winery Website: www.rebelcoast.com Introduced: May 2020 Distribution: California Product Snapshot: Rebel Coast’s existing Sauvage and Pink Passion beverages will now feature a new, refreshed brand look in ready-to-drink, easy-to-carry cans. They’ll also be offered in sparkling blends. Additionally, the Rebel Coast portfolio will expand to include three bubbly seltzers in Black Cherry, Lemon Lime and Mixed Berry flavors. Each 12-oz. product will contain 10 mg of THC. “All of our new products bring people the same delicious, low-calorie alcohol alternative they have come to love and expect from Rebel Coast,” said Rebel Coast CEO Josh Lizotte. “Our goal is to become the go-to house of cannabis-infused beverages, and these new innovations are absolutely a step in the right direction.”
Medical CannabisInfused Chocolate Bars Company: Coda Signature Website: www.codasignature.com Introduced: March 2020 Distribution: Colorado Product Snapshot: Coda Signature has released new infused chocolate bars with expanded dosage options for medical patients. The new line features Coda Signature’s classic bestselling flavors: Coffee & Doughnuts, Cream & Crumble, Caramel & Corn, Snap & Spice and Maple & Pecan. To meet the needs of medical cannabis patients who require increased amounts of cannabinoids for efficacious treatment of qualifying conditions, Coda Signature has created more formulations for its multi-serving chocolate bars. Coda Signature is offering a limitededition 1,000 mg THC Coffee & Doughnuts bar. The portfolio also includes Coffee & Doughnuts, Cream & Crumble, Caramel & Corn and Maple & Pecan with 500 mg THC. And for the patient seeking a CBD-THC option, the company is launching its Snap & Spice bar in a 500 mg THC and 500 mg CBD combination.
THC-Infused Beverages Company: Calexo Website: www.calexo.co Introduced: March 2020 Distribution: California Product Snapshot: Made with all-natural juices, botanicals and nano-emulsified THC (10 mg per 22-oz. bottle), Calexo beverages are precisely dosed for an easy-to-control, uplifting experience. Launched in two flavors, Citrus Rose and Cucumber Citrón, Calexo was initially available via delivery throughout Los Angeles from Sweet Flower Melrose or Sweet Flower Arts District dispensaries. Product availability was set to expand statewide in California, and starting fall 2020, BevCanna will be the exclusive manufacturing partner for Calexo in Canada. The suggested retail price is $20 per bottle.
CBD Instant Coffee Company: CBD Living Website: www.cbdliving.com Introduced: March 2020 Distribution: Nationwide Product Snapshot: Available in three flavors — Original, Golden Milk and Matcha — CBD Living Instant Coffee contains 250 mg of broadspectrum U.S.-grown organic hemp per 2.5-oz. container (approximately 7 mg of CBD per serving). Each flavor contains 100% Colombian Arabica coffee and is vegan, gluten-free, THC-free and non-GMO. To use CBD Living Instant Coffee, scoop one teaspoon of any flavor into a cup then add hot water, cold water or milk.
cannabis products | June 2020 23
| packaging |
BRANDING
ENGAGING TODAY’S
CANNABIS CONSUMER Distinct consumer populations are emerging, illustrating diverse future directions for the industry.
C By Douglas J. Peckenpaugh Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media. 24 cannabis products | june 2020
ompanies developing cannabis-infused foods and beverages—or looking to enter the market—have a wider playing field to work with in terms of target consumer demographics. In the wake of progressively expanding legislation opening legal cannabis markets across the U.S., we’ve discovered that today’s cannabis consumer comes from all walks of life, and product branding can take myriad viable forms.
CONSUMER INSIGHTS Jessica Lukas, senior vice president, commercial development, BDSA (for-
merly BDS Analytics), Boulder, CO, notes that BDSA insights emphasize that cannabis consumers span across generations, socioeconomic backgrounds, needs, and motivations. “The edibles category appeals to many, with continued popularity among cannabis consumers at around 69 percent usage,” says Lukas. “Even so, we are seeing a greater proportion of consumers who are young (18–34), single males (57 percent of edibles consumers) living in suburban areas with lower incomes (under $60k).” A strong, emerging demographic is more urban. “While edibles continue
| packaging | | consumer insights | Consumer insights from New Frontier Data, Denver, can help provide a better understanding of today’s cannabis consumer, based on consumption habits, preferences, and experiences.
CONSUMER ARCHETYPE
POPULATION PERCENTAGE
USAGE
INSIGHTS
Infrequent Conservatives
9%
Light
Older, recreational consumers who use cannabis a few times or less per year for relaxation
Silver Dabblers
14%
Light
Typically single, older men who use cannabis a few times or less per month for relaxation
Social Opportunists
17%
Light
Largest consumer group, people who use cannabis a few times or less per year in group settings
Discreet Unwinders
8%
Moderate
Mothers of adult children who have been using cannabis for decades while strongly believing in the health benefits of cannabis
Weekend Enthusiasts
11%
Moderate
Most often parents in their early 40s who consume cannabis regularly to decompress and enjoy their free time
Medical Purists
12%
Moderate
Most likely to use cannabis for its medical and wellness benefits, consuming daily, often by themselves
Functional Dependents
5%
Heavy
Young, hard-partying cannabis evangelists who spend more than $100 per month on cannabis
Modern Lifestylers
10%
Heavy
Young consumers with high incomes who consume a variety of product types for a range of reasons
Traditional Lifestylers
14%
Heavy
Young, diverse, single consumers who are high-spenders and consume cannabis daily
to be popular among the majority of consumers, the market is experiencing an interesting shift, with increased spending in the category coming from higher-income ($150K+), educated (technical school grads, college grads, master’s grads, or higher), professional and white-collar millennials residing in bigger cities,” says Lukas. The increasingly widespread availability of cannabis in the form of CBD is also a contributing factor, notes Lukas. “Increased access has meant wider exposure.”
Lukas notes 30 percent of U.S. consumers report that edibles is their preferred form of consumption, a proportion that has remained steady. “Among ‘acceptors’—U.S. adults (21+) who do not currently consume cannabis but would consider it in the future—a considerable 43 percent stated a willingness to consider edibles. This continued acceptance will prove essential in driving edibles growth.” While current spending and con-
sumption stems primarily from younger consumers (Gen Z, younger millennials), notes Lukas, there are a few American population segments representing a largely untapped market, including: • Generation X • Married couples with children • Politically conservative households • Service sector workers (e.g., retail workers) “Though still ‘untapped,’ when these segments do purchase products in the edibles category, spending is notably higher than average,” says Lukas. “The key to successfully breaking into these groups lies within meeting specific desired product attributes: members of these segments tend to value products made with all-natural ingredients with a higher CBD to THC ratio, and also value dosage and portion control. Finally, packaging matters to these groups, as they tend to seek more-attractive options that also allow for convenience of consumption and portability.” Cannabis has already broken into the mainstream, with widespread U.S. acceptance. “Mainstream acceptance is already healthy, with 69 percent of adults in fully legal U.S. states consuming or open to consuming cannabis,” says Lukas. “Cannabis as a mainstream product will most likely be the result of greater emphasis on innovation and niche-marketing to specific consumer groups. We expect to see this trend grow through 2020 and beyond, particularly as more states legalize and enable recreational cannabis sales.” Product branding has grown increasingly mainstream. “Cannabis products are now acting like consumer products, and packaging, branding, naming and visual merchandising/presentation are important components,” says Jackie DeLise, brand growth strategist, global wellness trends and design consultant, writer, speaker, educator, The Wellery, LLC, East Norwalk, CT. She points to product dynamics like taste, efficacy through dosing (including micro-dosing), portability, quality, brand reputation, communications, and ease of dispensability as impacting consumer relevance.
RECREATIONAL VS. MEDICAL Segmentation can occur based on recreational vs. medical use. “Demographics cannabis products | june 2020 25
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| packaging | continue to evolve around usage, generally with a younger group for recreational, and skewing older for medicinal,” says DeLise. But she notes perspectives on recreational and medical cannabis are starting to shift. “Research has discovered changing attitudes among the fastest-growing population segment of cannabis users: adults ages 60 and older,” says DeLise, referencing the “Measuring Attitudes toward Medical and Recreational Cannabis among Older Adults in Colorado,” study that appeared in the May 14, 2019, issue of journal The Gerontologist. The study was funded by the Colorado Department of Public Health and Environment. This research shows that seniors are blurring the lines between medicinal and recreational cannabis use, says DeLise. “Data were collected from a 2017 cross-sectional survey of 274 older Coloradans ages 60 to 94, with a mean age of 72, about 65 percent of whom were women who were recruited from senior
centers, health clinics, cannabis clubs, and dispensaries statewide. The survey included 83 questions on a variety of topics exploring the attitudes, prevalence, predictors, patterns, and health outcomes relating to cannabis.” DeLise notes that while about 60 percent of older adults strongly agreed that the “use of medical cannabis is acceptable,” only about 30 percent strongly agreed on the general acceptability of adult-use cannabis. About 45 percent of the survey respondents reported using cannabis within the past year. Of these, 54 percent reported using cannabis both medically and recreationally. Those who used cannabis within the last year reported “improved overall health, quality of life, day-to-day functioning, and improvement in pain.” Respondents reported that the most-common reasons for cannabis use include treating arthritis and back pain, followed by anxiety and depression. “The survey found that many seniors are ex-
periencing age-related health-care needs, and some take cannabis for symptom management, as recommended by medical doctors,” says DeLise. The study also discovered a large and growing number of “naive users” trying cannabis for the first time, notes DeLise. “Also, and interestingly, the older demographic is trying to avoid opioid prescription drugs and have found cannabis to be an acceptable alternative.”
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| packaging |
cannabis products
PACKAGING
KacePack Cannabis Packaging Range Company: KacePack Website: www.kacepack.com Design Snapshot: KacePack offers several packaging options for leading cannabis brands across North America, including bottles, jars, tins and pouches. The company provides solutions with ASTM compliant child-resistant closures and thoughtful design features, to ensure the product stays safe and contaminant free. KacePack also has extensive manufacturing capabilities in Asia and in-house engineering and design teams. Hippo Premium Packaging recently became KacePack’s first distributor in the U.S.
28 cannabis products | June 2020
| packaging |
Kinder-Safe Child-Resistant Packaging Dose Dial Company: Dosist Website: www.dosist.com Design Snapshot: Dosist has introduced Dose Dial, a discreet dispenser that issues 3.7 mg dissolvable tablets with a push of a button and the turn of a dial. Each dispenser contains 30 peppermint-flavored, sublingual tablets of Dosist’s calm or bliss formulations. Made with medical-grade materials, the dispenser is child-resistant and recyclable. The device retails for $30.
Company: Denali Innovations Website: www.denali-innovations.com Design Snapshot: Kinder-Safe is a line of child-resistant packaging solutions serving the medical and recreational cannabis industry. Developed by Denali Innovations and certified under 16 CFR 1700 requirements, Kinder-Safe packaging solutions utilize proprietary child-resistant technologies that meet the specific needs of the cannabis industry. Included in the Kinder-Safe line is Kinder-Lok, a child-resistant box which features a sliding sleeve and tray design. The injectionmolded tray, comprised of Plant Fiber Plastic, securely engages the outer sleeve via a patented locking tabs system. The Kinder-Safe line also includes Kinder-Zip, a flexible pouch that features a patented child-resistant zipper closure. This closure, in conjunction with the barrier film used to construct the pouch body, allows Kinder-Zip to maintain product freshness while preventing access by children.
Sublingual Micropearl Dispenser Company: Evielab Website: www.evielab.com Design Snapshot: Evielab’s patent-pending micropearl technology dissolves quickly under the tongue and is as discreet as a breath mint. Each pearl consists of purified CBD and CBG (cannabigerol) combined with natural terpenes. They come in effect-based profiles that may provide energy for sports performance, pain relief, relaxation, sexual drive, sleep, immunity and brain focus. Evie pearls are all natural with no additives, sugar, GMOs, or THC. The unique dispenser for Evie pearls delivers an exact dose of 5 mg in each pearl. The pharmaceutical-grade plastic capsule, injected at the highest level to meet stringent clean standards, measures out a single pearl dosage. The dispenser is designed to “pop” the pearl into the mouth without any cross-contamination among users.
Clear Glass Ergo Food Jars Company: Berlin Packaging Website: www.berlinpackaging.com Design Snapshot: Made with flint glass, the cylindrical shape of the Bruni Glass Ergo Food Jar will give products artisan appeal. Available in 7-oz. and 10-oz. capacities, the Ergo jar offers ample space for labeling while allowing customers to see the product inside. Ergo jars feature a deep lug finish and are not compatible with screw-top caps. A lug finish consists of several tapered ridges designed to mate and require only a partial turn to seal the cap. Caps include a PVC-free Blue Seal closure gasket which keeps product safe from contaminants.
cannabis products | June 2020 29
| ingredients |
CANNABINOIDS courtesy of Axiomm Technologies
CAPITALIZING ON ENCAPSULATION Applying encapsulation and emulsification methods increases cannabinoid bioavailability, shelf stability in food and beverage products.
A
By Alyse Thompson Alyse Thompson is managing editor of Cannabis Products. 30 cannabis products | june 2020
s cannabis-infused food and beverages gain popularity among consumers, manufacturers and brand owners face the challenge of consistently incorporating cannabis oils into their products. The hydrophobic nature of cannabis oil doesn’t make using it easy—particularly in water-based products—but applying encapsulation and emulsification techniques offer a variety of benefits, says Andrew Wong, president, Axiomm Technologies, Calgary, Alberta, Canada. First and foremost, encapsulation allows for even dispersion throughout the product, meaning consumers will get the same amount of an active ingredient, such as cannabidiol (CBD) or tet-
rahydrocannabinol (THC), in each bite or sip. “You avoid situations where a sip of a drink might have you consuming most of the cannabis oil that’s sitting on top of the water layer in a beverage or, alternatively, where you consume none of that oil layer,” says Wong. Encapsulation also improves a product’s shelf life, preventing the cannabinoid content from degrading over time and keeping the formulation stable. Courtney Maltais, lead botanist and founder, The Clear, Denver, says proper emulsions should be invisible to the naked eye. However, a product can “crash out” and a layer of precipitate can appear at the bottom of a bottle or jar. “Oftentimes, crash out can be mediated by sim-
| ingredients | courtesy of Quicksilver Scientific
courtesy of Axiomm Technologies
ply shaking the substance; however, when it comes to mixing oil and water, this will not guarantee proper dispersion and dosing in the product,” she says. There are also the concerns of absorption and onset times. Properly encapsulated or emulsified cannabinoids are believed to enter the bloodstream faster and in greater amounts. For edible consumers, that’s especially important, since feeling the effects sooner can prevent inadvertent overconsumption. “Nanoemulsion-based products allow the consumer to feel buzzed anywhere from 2 minutes to 15 minutes after using or consuming a product,” Wong says. “This rapid onset time helps minimize overconsumption and also benefits consumers who are using cannabis for medical purposes such as pain relief.”
ENCAPSULATION METHODS Depending on the product being formulated, there are three types of oilin-water emulsions: macro, micro and nano. Key distinctions between these methods are varying levels of solubility, transparency and overall product quality, Maltais says. Macroemulsions, which have droplets that are 1 micron in diameter, lack shelf stability due to their low solubility. They also tend to be unstable and separate into a water layer topped by an oil layer, making them unsuitable for a water-based product or beverage. Microemulsions feature droplet diameters below 100 nanometers. These emulsions are translucent and thermodynamically stable mixtures of oil, water and surfactants, or emulsifiers. When using surfactants to make cannabis oil soluble in water, a higher concentration of surfactant is needed to encapsulate the cannabis oil. “This isn’t ideal because surfactants can have varying side effects and can undermine the taste and quality of the courtesy of The Clear cannabis products | june 2020 31
| ingredients |
CANNABINOIDS courtesy of The Clear
product,” Maltais says. “The high ratio of necessary surfactants poses a challenge for formulators to reach the desired cannabinoid concentration without exceeding the maximum permitted surfactant levels.” Nanoemulsions, the most widely used in the cannabis food and beverage industry, feature droplet sizes below 250 nanometers, with less than 100 nanometers being the ideal, as they are optically translucent. Additional benefits include low viscosity, high interfacial surface area and long-term kinetic stability. “Nanoemulsions are the most shelf stable and visually pleasing option and use roughly one-tenth the surfactants that other methods require,” Maltais says. “Nanoemulsions are completely water soluble as well.” Manufacturers can also turn toward liposomes, a way of encapsulating cannabinoid-rich oils with a dual layer of phospholipids, or microscopic fat particles. Liposomes are sphere-shaped vesicles that surround and protect the oil from degradation, harsh stomach acids and enzymes,
courtesy of Wana Brands
Wana on TiME In March, Wana Brands launched Wana Quick Fast-Acting Gummies using a patent-pending encapsulation technology from Azuca. Azuca’s TiME (thermodynamic individual molecular encapsulation) infusion process enrobes individual CBD or THC molecules to make them hydrophilic, allowing for faster uptake, beginning immediately in the mouth and avoiding the gut and liver where cannabinoids are degraded and absorption is slowed. This method transforms each individual molecule into a 15 angstrom-sized particle that is processed by the body’s endocannabinoid system in minutes. Wana’s fast-acting gummies have an onset of 5–15 minutes with Delta-9-THC effects lasting up to three hours. Traditional edibles often have an onset time of up to two hours, with effects lasting up to six hours. “At Wana, we saw a need for a product that could deliver a less-intense, inhalation-like experience in an edible form quickly and predictably,” says Nancy Whiteman, CEO, Wana Brands, Boulder, CO. “Wana Quick Fast-Acting Gummies more closely mirror the onset and offset time of a typical
32 cannabis products | june 2020
inhalable cannabis product or an alcoholic beverage, making them a unique alternative to the traditional edible experience.” Wana Brands and Azuca first announced their partnership in October 2019, highlighting the benefits of edibles with faster onset periods. “The partnership with Wana Brands allows us to bring our fast-acting culinary technology to a large universe of cannabis consumers for a more controlled and positive experience,” says Kim Rael, president and CEO, Azuca, New York. “We look forward to long-term growth and success.” Available in cocktail-inspired flavors, the Wana Quick range includes CBD/THC 1:1 Strawberry Margarita, Sativa Peach Bellini, and Indica Piña Colada. Each piece contains 5 mg of THC or CBD.
| ingredients | and processing by the liver. Their structure allows the cannabinoid content to get into the bloodstream quicker and more chemically intact, says Christopher Shade, Ph.D., founder and CEO, Quicksilver Scientific, Louisville, CO. “The smaller the spherical liposomes, the easier it is for them to penetrate into the bloodstream and into the targeted cells,” he says. “Quicksilver Scientific engineers liposomes in the 20–100 nanometer range.” Maltais added liposomes are more compatible with synthetic or isolated cannabinoids, rather than less-refined or full-spectrum oils. She says they can create slightly more shelf-stable emulsions than macro- and microemulsions. “This process involves complex preparation procedures and very high surfactant concentrations,” Maltais says. “It still does not compete with nanoemulsions, which are equally shelf stable and far easier to produce in a standard manufacturing facility.”
MARKET TECHNOLOGY Quicksilver Scientific has plenty of experience with lipid particle delivery systems, but some of the supplements it works with aren’t compatible with its traditional liquid format. As a result, the company developed the patent-pending Self-Emulsifying Delivery System (SEDS), which is a solid dose soft-gel form that provides high bioavailability and absorption while avoiding some undesired flavors and staining. “When Quicksilver Scientific utilizes the new SEDS technology, pharmacokinetic studies indicate that the softgel quickly dissolves in the stomach creating emulsified nanoparticles that easily diffuse through intestinal cell membranes into the bloodstream in as little as 20 minutes with peak blood concentration occurring within 90 minutes,” Shade says. For nanoemulsions, Axiomm offers the μGOO precursor technology that’s compatible with a range of oils, vitamins, and nutraceuticals. Wong says it took years of reformulating and stress-testing to hone a
solution that serves its customers. SōRSE Technology, Seattle, WA, offers a patent-pending emulsion technology that appears in more than 30 market-leading products. It surrounds cannabis oils and oil-based terpenes, transforming them into a water-compatible format. It’s available in liquid, standard powder and agglomerated powder formats. SōRSE says products using its technology have an even dispersion of cannabinoids, and their effects are felt in 10–20 minutes. Products using SōRSE remain stable for roughly 12 months. Regardless of the system manufacturers use, Wong cautioned against rushing through the R&D process just to get a product on the market. “Building a product on the back of a poor-quality emulsion can do your brand far more harm than choosing to stick to traditional oilbased products. Take your time and be sure that you’re sure the nanoemulsion you’re using is a quality one.”
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cannabis products | june 2020 33
| ingredients |
cannabis products
INGREDIENTS
Water-Stable CBD Formulation Company: Ananda Scientific Website: www.anandascientific.com Ingredient Snapshot: Ananda Scientific has developed a water-stable formulation using the company’s patented, high-bioavailability Liquid Structure CBD. The Liquid Structure formulation offers the technology to deliver cannabis-infused beverages to market in plastic, glass and aluminum packaging without affecting the potency of the liquid for broader, more cost-effective distribution. “Ananda’s innovative patented delivery technology (United States Patents 7,182,950 and 10.149,824) presents tremendous new opportunity for worldwide expansion of the CBD beverage sector,” says Mark J. Rosenfeld, CEO and chief science officer, Ananda Scientific. “We are excited to be paving the way through sound science with the first high-bioavailability cannabinoid formulation that stays in solution and otherwise remains stable at all ends of the supply chain.”
34 cannabis products | June 2020
| ingredients |
Water-Soluble CBD Ingredients Company: Prinova, Open Book Extracts Website: www.prinovausa.com; www. openbookextracts.com Ingredient Snapshot: Prinova, a supplier of ingredients, flavors and nutrient premixes, has partnered with Open Book Extracts, a CBD ingredient manufacturer, to launch a new line of water-soluble CBD ingredients. The HydroBond CBD line was developed and processed in-house at Prinova, using Open Book Extracts’ premium hemp-derived CBD ingredients. The two companies will collaborate in the product development and formulation of solutions for CBD consumer products, utilizing the increased performance of HydroBond CBD in liquid solution and powder RTM applications. HydroBond CBD has unique benefits, offering the ability to blend effectively and deliver neutral taste. Consumer demand for a “clean label” is also being addressed, particularly in the patent-pending HydroBond CBD Powder, which utilizes acacia fiber as the sole carrier.
Silver Plume CBD Oil Company: Kazmira LLC Website: www.kazmira-llc.com Ingredient Snapshot: This THCfree, broad-spectrum CBD oil contains no cutting agents such as propylene glycol or vegetable glycerin. Suitable for gummies, it has a gold to light amber color, a neutral taste and a strong floral fragrance. It has 40–60 percent CBD by weight, as well as 3–5 percent of terpenes by weight and 3–8 percent by weight of cannabidivarin (CBDV), cannabigerol (CBG), cannabichromene (CBC) and cannabinol (CBN).
NanoLyte Water-Soluble CBD Company: Beneficial Blends Website: www.beneficialblends.com Ingredient Snapshot: NanoLyte is certified-organic water-soluble CBD, with non-detectable THC. Its natural, mild taste features high bioavailability (rate of absorption), water compatibility (easily mixed into beverages) and long-term product stability. The product is available in a liquid, powder or tablet format.
Functional Flavor Blends Company: Abstrax Tech Website: www.abstraxtech.com Ingredient Snapshot: Abstrax Tech’s Functional Flavors, which are presented in the form of both water-soluble and oil-soluble botanical blends, have arisen out of the company’s understanding of cannabis and the power of botanically-derived flavor and aroma compounds (terpenes) for more complex flavor blends and aroma profiles. The company has developed more than 200 complex terpene profiles, leveraging purified, food-grade terpenes derived from orange, lemon, basil, lavender and chamomile, among others. One of Abstrax Tech’s newest product offerings is water-soluble blends packaged in a “Keg Kit” for beer brands. The kit gives brewers the ability to perform their own product development while considering both beer flavoring and the effects delivered by each terpene blend.
cannabis products | June 2020 35
| equipment |
AUTOMATION courtesy of Erika Record Baking Equipment
ADVANCING
THROUGH AUTOMATION Automating select aspects of cannabis-infused food and beverage production can bring strategic advantages.
E By Douglas J. Peckenpaugh Douglas J. Peckenpaugh is the group editorial director of snacks, bakery, meat, candy, food safety, and cannabis at BNP Media. 36 cannabis products | June 2020
ver since California opened the door to legal sales of medical cannabis in 1996, cannabis-infused foods and beverages have been commercially available. Similar legislation progressively made its way across the U.S., providing relief for a wide range of conditions and ailments. Entrepreneurial businesses sprung up around legal cannabis to meet demand, and the nascent roots of a cottage industry began to grow. But it wasn’t until 2014 when Colorado passed legislation permitting recreational cannabis use that this industry began to see exponential growth. More states followed suit, and in 2019, sales of legal cannabis in the U.S. reached $12.2 billion according to the 2020 update to “The State of Legal Cannabis Markets” report released in January 2020 from Arcview Market Research and BDSA.
But the best is yet to come. We are on the cusp of a new age of cannabis food and beverage product development. Passage of the 2018 Farm Bill nationally legalized non-psychoactive cannabidiol (CBD) derived from industrial hemp. And all eyes are now on FDA to provide guidance for use of CBD in foods and beverages. Once that final piece of the puzzle is securely in place, foods and beverages infused with CBD will become available to U.S. shoppers. With this level of growth comes the need for more-sophisticated equipment, technology, and strategies to meet a far-greater demand for cannabis-infused foods and beverages. And incrementally adding automation to production processes is a great place to start.
INCREASING EFFICIENCY There are multiple ways to measure efficiency gains when looking to automate
courtesy of Andy J. Egan Co.
your production, says Daniel DaRocha, president, Erika Record Baking Equipment, West Caldwell, NJ. “Of course, the first gain is always in being able to produce more product. With automation, you can extend your single product production runs, and minimize changeovers and downtime. In addition to longer runs, with increased automation there are gains of consistency, both in size and appearance.” He notes that automation also reduces the need for employees to handle the product. Most of the work that Egan Food Technologies, Grand Rapids, MI, has done in the cannabis industry has been in chocolate molding and depositing, says Mike Sherd, managing partner. “We’ve helped some of the industry’s most well-known brands automate these steps in their processes in ways that allow them to scale when they’re ready for additional automation. By starting with just one step in the process—as opposed to an entire equipment line—most producers can manage automation with their existing staff.” It’s also important for producers to have an end product that’s scalable, and to be open to slight process changes that will make automation possible, says Sherd. “For instance, the size of the product may need to be adjusted or the recipe tweaked when moving from a hand-forming process to automation. This also creates uniformity in the look of the final product, but more importantly, consistency for ingredients and dosages. For infused chocolate, there can be a lot of wasted and unaccounted for ingredients if your current process includes flooding a mold or filling every cavity by hand. A simple depositor can typically have a quick ROI for this reason alone.” Automating the packaging process is another strategic area that can bring increased efficiency and quality. Nick Roelse, national sales and key accounts manager, Viking Masek, Oostburg, WI, notes that there are three critical keys to maximizing performance when it comes to automated cannabis packaging lines: 1. Ensuring the multi-head scale is fed appropriately 2. Weighing the product with speed and precision 3. Accuracy and smooth transition into the finished package These variables might sound simple, says Roelse, but can be difficult to achieve without proper expertise and experience. “Partnering with the right equipment man-
| equipment |
ufacturer is a massive differentiator when it comes to successfully increasing production efficiency through automation.” When making an investment in packaging automation, equipment lead times of weeks to months must be taken into consideration, says Roelse. “For this reason, it’s key to purchase based off both existing and future capacity demands. Typically, we tell customers to purchase for at least six to eight months of future capacity on top of current demands.”
INCREMENTAL GROWTH Producers of cannabis-infused foods and beverages can strategically set up early stages of automation so that the equipment can grow with them as they add increased capacity and/or other product lines in the future. “This is all based on number of the employees and options available,” says DaRocha. “There are always basic ways that you can increase automation.” This might include purchasing larger mixers, larger ovens, and incorporating depositing/portioning machines. “However, these decisions must be made inclusive of the larger picture,” says DaRocha. “For example, when you increase automation at the beginning of your production line—such as larger mixers—without addressing your downline equipment, you will create a bottleneck, or have product unnecessarily sitting and waiting. Likewise, if you increase automation further down line—larger ovens, cooling tunnels, dehydrators—but not in the beginning of the production line, you may not be utilizing
your equipment to its fullest.” This does not mean that a cannabis food and beverage producer should purchase a full line earlier than they need it, though, says DaRocha. “You should start by asking yourself if your company is maximizing efficiencies with their current employees and space. Could production flow be improved?” In the early stages of establishing automation, cannabis-infused food and beverage manufacturers should seek out an equipment supplier who will be a partner through all stages of growth, says Sherd. “It’s very typical for customers who are currently hand-forming their products to start with a base depositor. When they’re ready for additional automation, they can look upstream and add a mixing tank or liquid doser to supply the depositor. Downstream, they could add mold shaking, product cooling, and/or automatic demolding over time. Because of our modular designs, Egan Food Technologies’ equipment is ideal for supporting our customers’ growth when they increase capacity in the future.” When initially starting to work with a new or prospective customer, Egan Food Technologies will have the manufacturer typically send in sample products to evaluate, along with a video of their current production methods. “Sometimes we travel to the customer’s facility to see this process firsthand,” says Sherd. “Back at our headquarters, we put their products through a series of tests to ensure it can be automated, and then we discuss which equipment might be the best solution for their product,” continues Sherd. “After the equipment is built, we’ll run factory acceptance tests in our shop. Customers can visit during that time to see their products running on the equipment, or we can provide video footage as an alternative to travel.” Egan Food Technologies also provides installation and training. “Over time, we stay in contact with our customers to determine when they’re ready to add the next level of automation,” says Sherd. “It’s common to have a wish list of solutions from the very beginning, but to add those little by little so that customers can scale up automation at the right pace for their business.”
OVERALL IMPROVEMENTS Automation creates significant improvements in product consistency and accuracy, says Sherd, which is directly linked to cannabis products | June 2020 37
AUTOMATION
| equipment | both quality and safety—especially in the cannabis industry. “Manufacturers can be more confident in the dosage of each product, and there are fewer overall touchpoints from humans. Oftentimes, products must be deposited at temperatures in excess of 200˚F, which creates burn risks when being done by hand. In that same scenario, a mold that’s being scraped by hand to remove excess product is going to have less uniformity than one being deposited according to specific measurements.” Companies looking to add automated production solutions should also consider how the product may be handled, and how an existing recipe or production process may need to be adjusted to better accommodate the mechanization and automation of your production line, suggests DaRocha. It’s always important to do your research prior to committing to an equipment purchase, says DaRocha. “This includes familiarizing yourself with local installation requirements and any potential production challenges during your transition to more-automated solutions.” Erika Record
Baking Equipment offers hands-on and virtual demonstrations for customers, including availability of staff bakers to provide support, a comprehensive spare parts inventory, and delivering customer service both during and after the sales process. “Our team includes experienced bakers who understand your unique production needs,” says DaRocha. “We are able to have an honest conversation about a company’s current production and projected growth.” Removing the potential for human error from the packaging process poses benefits, says Roelse. “It’s extremely consistent and repeatable, which increases product quality and safety. With automated packaging machines handling the process, the product can be handled in a way that’s specific to its needs, which ensures the best product quality.” Safety risks and hazards are also significantly reduced, both for the worker and the consumer. “This is especially important during a public health crisis, when minimal human involvement is both desired by consumers and a reality, with workers being in short supply.”
Viking Masek provides a certified technician that travels to a customer’s facility to help install, commission, and train employees on the new machine, says Roelse. “After the technician goes home, we continue to provide full-service support the customer with a dedicated team consisting of mechanical and electrical experts who are available around the clock to make sure our customers are maximizing machine performance and uptime.” Cannabis food and beverage companies are often made up of great teams with visions for exceptional products, says Sherd. “They know marketing, sales, and business operations, and have a great understanding of the industry, but they don’t always see themselves as having the technical knowhow for automation. Because of this, we see some manufacturers leaning into co-packing instead of investing in their own equipment. But with the right equipment partner in place, producers can confidently transition to automation, and it’s only going to help their business in the long run.”
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38 cannabis products | June 2020
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| equipment |
cannabis products
EQUIPMENT
Bottle and Cap Vision Inspection System Company: Silgan Equipment Website: www.silgancls.com Equipment Snapshot: The Silgan Equipment 51R56 vision inspection system inspects filled bottles for loose, skewed and missing caps, damaged or missing tamper-evidence bands, and low fill levels. Additional available system options include confirming proper cap color and graphics. The system efficiently detects and rejects incorrectly capped, damaged or incompletely filled containers before they can proceed downstream and enter the marketplace. Silgan Equipment has upgraded the 51R56 system to version 51R56G by replacing the previous cameras with high-resolution GigE Flir cameras. At the same time, previous Windows 7 operating system software has been replaced by new software operating on Windows 10. The unit’s multiple cameras conduct 360-degree inspection of passing containers. The vision tunnel is mounted on a stand that enables the unit to be positioned easily over an existing conveyor line, eliminating the need to break into a line to provide space. This configuration also enables the unit to be quickly raised or lowered as it inspects different height containers. The 51R56G can inspect cap sizes from 28 mm to 43 mm, and up to 82 mm with changes to camera lenses and lighting. The vision unit tunnel includes a motorized height adjustment that adjusts the unit as the recipe for a new bottle height is activated. Custom LED lighting within the tunnel supports clear visual images. Both the HMI and the vision unit are NEMA 4X rated, providing watertight washdown protection.
40 cannabis products | June 2020
| equipment | Mobile Inline High-Shear Mixers Company: Charles Ross & Son Company Website: www.mixers.com Equipment Snapshot: ROSS Inline High-Shear Mixers accelerate mixing, emulsification and homogenization in both recirculation and continuous modes. A mobile skid allows these machines to be used anywhere in a plant, saving time and money by eliminating the need for multiple mixers separately dedicated to each vessel or product. Easy to clean in place and relocate, the pictured ROSS Model HSM-410 Inline High Shear Mixer is a versatile machine capable of handling different applications with viscosities up to 20,000 cP. A VFD or control panel may be mounted to the cart and wired to the mixer motor for complete portability. Sanitary models are available with tri-clamp inlet/outlet connections and a one-piece stator/ chamber cover for even quicker disassembly and clean-up. Ultra-high shear designs are offered as well.
Selmi Plus EX Chocolate Tempering Machine Company: Tomric Systems, Inc. Website: www.tomric.com Equipment Snapshot: Able to temper 52 lbs. of chocolate in 15 minutes, this tempering machine features a digital control panel and pump screw that can be removed in 5 minutes for easy cleaning. This stainless steel unit features in-tank agitation/mixing arms, foot pedal chocolate flow control, digital thermostatic controls and a built-in vibration unit. Enrobing attachments and cooling tunnels up to 4 meters in length are also available.
Triple-Chuck Capping Machine Company: ValTara S.R.L Website: www.valtaratec.com Equipment Snapshot: The ValTara automatic triplechuck capping machine is capable of accommodating various size jars and meeting production rates up to 100 cycles per minute. A conveyor continuously feeds bottles, containers or jars to the star wheel. Chuck assemblies are rotated on the turret of the rotary capping machine. Empty chucks pass over the swinging arm carrying each cap for automatic pick and place. As each chuck is precisely lowered over the container, the turret continues to rotate and the cap is precisely aligned with the revolving bottle, container, or jar then accurately torqued. Then chuck assemblies release the cap and the chuck rises while capped bottles are neatly discharged from the machine.
Table-Top Universal Mould Depositor Company: Savage Bros. Co. Website: www.savagebros.com Equipment Snapshot: This depositor is used for manual, metered deposits of chocolate, caramel, gummy and hard candy into moulds. Manual operation allows for gentle depositing to give an improved product quality. The digitally controlled, heated hopper, allows for working with higher temperature settings and filling 6 to 8 mould cavities at once. The maximum temperature is 320°F/160°C.
cannabis products | June 2020 41
SANITATION
| equipment |
courtesy of Spraying Systems
SANITIZING FOR SAFE
EDIBLES Even without federal oversight, cannabis food and beverage manufacturers should follow GMPs for equipment cleaning and sanitization.
W
By Alyse Thompson Alyse Thompson is managing editor of Cannabis Products. 42 cannabis products | june 2020
hether manufacturers make cannabis-infused foods and beverages or non-infused ones, proper sanitation is a must to create safe, high-quality products. And while there’s no federal oversight of cannabis-infused food manufacturing—and states have their own patchwork of regulations—manufacturers of cannabis products should still follow the rules governing non-infused food production, says Tim Robb, vice president, market-
ing and strategic business development, Goodway Technologies, Stamford, CT. “Maintaining clean and sanitized environments built on well-defined good manufacturing practices (GMPs) and standard sanitation operating procedures (SSOPs), and staffed with professional sanitation and maintenance managers, will help increase the quality and safety of end products,” says Robb.
SYSTEM CONSIDERATIONS Many food manufacturers rely on clean-in-place (CIP) methods, which al-
courtesy of Goodway Technologies low for the cleaning and sanitization of pipes, vessels, filters, fittings, and other processing equipment without disassembly. Alternatively, clean-out-of-place (COP) methods require equipment to be disassembled and moved from their positions to be thoroughly cleaned (for comprehensive federal guidelines for cleaning and sanitizing food and beverage production facilities, see 21 CFR 117). Under both methods, cleaning systems should incorporate TACT principles—time, action, chemical, and temperature—developed in the late 1950s by chemical engineer Herbert Sinner. These principles determine the result of the cleaning process. How they’re applied requires understanding the composition of the food product being manufactured. Aspects like solubility, total solids, product pH, and the potential for bacterial contamination and growth all might require consideration. Total loading of residual product particle adherence can also factor into sanitation requirements. This can be an issue with the sticky, highly viscous cannabinoid oils used in manufacture of infused products. It’s also important to only use sanitation methods and systems specifically developed for use in food-contact manufacturing environments, says Robb. “Is the technology implemented explicitly developed for food production environments? For example, does it include cleanable surface or industrial design with limited food collection areas?” Another element to consider is the total cost of ownership—and not just for the equipment itself. Labor, water usage, and chemical usage are expenses to factor in, as well. The type of chemistry also makes a difference, says Keith Cronce, director of PathoSans/Klarion Groups, Spraying Systems Co., Wheaton, IL. Some cleaning and sanitation systems rely on purchased chemistry, while others produce it onsite, eliminating the need to purchase chemicals from outside suppliers and minimizing potential supply chain disruptions. “No matter which decision is made, the effectiveness of the chemistry is critical,” says Cronce. “Then the safety of the chemistry should be considered. Concentrates are toxic and require special storage, handling, and worker training. Sanitation systems that produce chem-
istry on-site using electrochemical activation (ECA) technology can reduce the risks to workers and save time.”
| equipment | This process happens right in the customer’s facility and provides these two solutions in ready-to-use concentrations. The solutions are just as effective as conventional chemicals, but without the health risks for workers.” Cronce notes the system has been effective on removing organic fats and oils, factors that support using the Klarion system in production facilities used to manufacture cannabis-infused foods and beverages. Heating the cleaner increases the effectiveness of removing some oils. Cronce also pointed to the sustainability benefits of the Klarion system, which could be important to cannabis edibles manufacturers with values related to supporting the health of the environment. “The Klarion OSG system eliminates the pollution associated with delivery of conventional chemicals by producing chemistry onsite and on demand. It also
SYSTEMS ON THE MARKET Cronce says the Klarion system works off the process of electrolysis. Through patented electrolytic cell technology, it takes salt and water and converts them into a cleaner/degreaser and a sanitizer/ disinfectant. “Our generator separates the sodium (Na) and chlorine (Cl) and sends them to two different chambers of the cell,” says Cronce. “One chamber creates our sodium hydroxide-based cleaning solution (NaOH). The second chamber creates our hypochlorous acid-based sanitizer/disinfectant (HOCl), which is an extremely effective killer of microorganisms, including viruses and bacteria.
courtesy of Goodway Technologies cannabis products | june 2020 43
| equipment | eliminates the need to dispose of or recycle chemical containers. Both the cleaner and sanitizer are drain- and disposal-friendly.” Goodway Technologies offers dry steam systems, which use superheated steam technology. Water is turned into vapor and then heated further under pressure to reduce the water moisture level, yet retain the cleaning and sanitation performance. Robb says dry steam has about 5 percent moisture by volume, significantly reducing the amount of water used versus saturated steam. “Dry steam solutions work well on sticky residues,” Robb says. “The high heat and low moisture content quickly liquefy oils, allowing for quick and effortless removal.” Goodway also offers BIOSPRAY systems, which use a combination of a patented spraying system and alcohol-based BIOSPRAY-D2 sanitizer. “The alcohol in the sanitizer provides some fantastic ben-
SANITATION efits to food producers, as it has terrific sanitation performance but evaporates very quickly,” Robb says. “Surfaces can be sanitized rapidly and effectively. The challenge with alcohol is its flammability. The BIOSPRAY system uses patented CO2 propulsion technology to envelop the BIOSPRAY-D2 with CO2 gas, significantly reducing its flammability during application. It also uses a lab-calibrated spray system that produces microdroplets of the liquid sanitizer, increasing coverage consistency and reducing chemical usage. This technology allows for widespread application of the alcohol sanitizers, faster and easier than existing hand-wiped or ‘spray and wipe’ technology.” Additionally, Goodway offers heat exchangers, which transfer heat between fluids, for sterilization and pasteurization, as well as for heating and cooling throughout the production process.
Heat exchanger cleaning systems come in mechanical and chemical solutions, depending on the deposits that need to be cleaned, Robb says. “Our mechanical systems generally utilize rotating technology, where a brush is attached to the end of a long shaft and mechanically rotated— along with a water flush—to clean and flush deposits. Chemical solutions are used primarily for calcium/limescale deposits and are flushed through using pumping systems to remove deposits.” No matter which system is used, having properly trained employees to lead and carry out sanitation procedures is crucial, Cronce says. “Food plant sanitation is not the most glamorous job. It is however an extremely important one. The safer the process, the higher the likelihood that employees will stick around.”
| ad index | company name Admix
website
page number
admix.com
21
Caputo Cheese/Elevated Cow
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Carmi Flavors
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Back Cover
CPX20 Cannabis Products Exchange Fortress Technology MoistTech Corp. ROSS Mixers Sweegen
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2, 20, Inside Back Cover
fortresstechnology.com
33
moisttech.com
38
mixers.com/cbd
1
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Inside Front Cover
This index is for the convenience of our readers. Every care is taken to make it accurate. Cannabis Products assumes no responsibility for errors or omissions. 44 cannabis products | june 2020
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