ProFood World June 2018 by PMMIMediaGroup

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June 2018

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ProFood World

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Month 2017

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June 2018

CONTENTS

Cover photo by Katina Reist Photography.

From the Editor

In the News

Risk management often involves supplier certifications, lack of GMPs or disgruntled employees. Today, risk is not only in your supply chain and plant, but in potential capital equipment expenditures.

PMMIâ&#x20AC;&#x2122;s OpX Leadership Network developed a request for proposal (RFP) template that will help stakeholders involved in the RFP process gain greater understanding of their project requirements and deliver capital project excellence.

OpX Intel: Factory Acceptance Tests The more complex or custom the project, the greater the value it will derive from an in-depth review of the factory acceptance test protocol.

Packaging Technology

COVER STORY

Penn State University uses crab shells and wood to create an inexpensive, eco-friendly biomaterial that could be a sustainable alternative to plastic and reduce pollution.

Dairy Farmers of America uses redundant systems and advanced automation systems to keep its processes running 24/7.

Sanitary Plant Design

Dry Processing Solutions

Plant Floor New Products

Case Study: Java Jolt

Machine Safety

An effective sanitary plant design minimizes risk by preventing pathogens from infiltrating the facility while still ensuring the plant is productive and can be cleaned down to a bacteriological level.

Bulk bag dischargers and flexible screw conveyors give Once Again Nut Butter a higher degree of automation and control to double production capacity and improve operator safety. Bulk and dry processing equipment solutions follow this lead story.

An inside look at the latest technology for pest control and mixing and blending equipment.

Fast-paced growth pushes Bean Box to upgrade to an automatic rotary premade pouch filling machine to speed up its packaging process and reduce labor costs.

A proper risk reduction protocol protects employees and equipment by identifying potential hazards; focusing on reducing risk, not scoring it; and determining what is acceptable risk. www.profoodworld.com

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June 2018

ProFood World

5/29/18 4:24 PM

ProFood World ISSN 2476-0676

EDITOR - IN - CHIEF JOYCE FASSL

Mobile: 610/547-9814 jfassl@pmmimediagroup.com

The Most Advanced Steam Boiler Technology

MANAGING EDITOR MAYA NORRIS

312/205-7898 mnorris@pmmimediagroup.com CONTRIBUTING EDITORS JEFFREY BARACH , GRANT GERKE, ROY GREENGRASS , JEANNE SCHWEDER

B U S I N E S S S TA F F PUBLISHER PATRICK YOUNG

610/251-2579 pyoung@pmmimediagroup.com DIRECTOR , BUSINESS DEVELOPMENT CAROLYN DRESS

312/205-7912 cdress@pmmimediagroup.com

BRAND OPERATIONS MANAGER CLAUDIA SMITH

312/222-1345 csmith@pmmimediagroup.com

ART

ADVE R TI S I N G SALE S

CREATIVE DIRECTOR DAVID BACHO

PUBLISHER PATRICK YOUNG

ASSOCIATE ART DIRECTOR MORGAN HUNECK

TECHNOLOGY

SENIOR VICE PRESIDENT, DIGITAL AND DATA DAVID NEWCORN SENIOR DIRECTOR , DIGITAL INFRASTRUCTURE ELIZABETH KACHORIS DIRECTOR , WEBSITE PRODUCT MANAGEMENT JEN KREPELKA DIGITAL PROJECT MANAGER JOURDAN DUNN

MANAGER , DIGITAL INFRASTRUCTURE JOAN JACINTO

SENIOR WEB DEVELOPERS YEVGENY ANANIN , ANDREW TATE WEB DEVELOPER DOUG DOBRZYNSKI

PUBLISHING PRESIDENT JOSEPH ANGEL

VICE PRESIDENT, CONTENT AND BRAND STRATEGY

JIM CHRZAN DIRECTOR , MARKETING SUE DAMARIO MARKETING MANAGER AMBER MILLER

S AV E S FUEL

EXECUTIVE ADMINISTRATOR JANET FABIANO

S AV E S S PA C E

AU DIE NCE DE VE LOPM E NT DIRECTOR OF AUDIENCE DEVELOPMENT JEN LADALSKI AUDIENCE DEVELOPMENT MANAGER BRUCE SPRAGUE

S AV E S TIME

AUDIENCE DATA ANALYST LAUREN SANZ

S AV E S MO N E Y

ADMINISTRATIVE SUPPORT MANAGER KATE MURPHY

pyoung@pmmimediagroup.com • 610/251-2579 DIRECTOR , BUSINESS DEVELOPMENT CAROLYN DRESS

cdress@pmmimediagroup.com • 312/205-7912 DISTRICT SALES MANAGER BRIAN J . GRONOWSKI

bgronowski@pmmimediagroup.com • 440/564-5920 REGIONAL MANAGER RICKY ANGEL

rangel@pmmimediagroup.com • 630/805-3892 REGIONAL MANAGER LEO GUENTHER

guenther@packworld.com • 904/377-7865 REGIONAL MANAGER JIM POWERS

jpowers@automationworld.com • 312/925-7793 REGIONAL MANAGER WENDY SAWTELL

sawtell@packworld.com • 847/784-0520 REGIONAL MANAGER CHRISTINE J . SMALLWOOD

csmallwood@pmmimediagroup.com 770/664-4600

PUBLISHER , AUTOMATION WORLD KURT BELISLE

kbelisle@pmmimediagroup.com • 815/549-1034 PUBLISHER , HEALTHCARE PACKAGING LIZ TIERNEY

tierney@packworld.com • 815/861-2992 PUBLISHER , OEM MAGAZINE JIM CHRZAN

jchrzan@pmmimediagroup.com 847/830-2915 CUSTOM MEDIA

DIRECTOR , CLIENT SUCCESS KELLY GREEBY

DIRECTOR , CUSTOM MEDIA SARAH LOEFFLER

O P E R AT I O N S PRODUCTION MANAGER GEORGE SHURTLEFF

800.423.4585 info@claytonindustries.com

ProFood World • PMMI Media Group 401 N. Michigan Ave., Suite 300, Chicago, IL 60611 Phone: 312/222-1010 • Fax: 312/222-1310 Email: info@pmmimediagroup.com • Web: www.profoodworld.com PMMI, The Association for Packaging and Processing Technologies 11911 Freedom Drive, Suite 600, Reston, VA 20190 Phone: 703/243-8555 • Fax: 703/243-8556 • Web: www.pmmi.org Staff at PMMI Media Group can be contacted at info@pmmimediagroup.com.

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June 2018

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CASE STUDY CASE STUDY CASE STUDY FROM THE EDITOR

IT’S ALL ABOUT THE RISK MITIGATION Leaving nothing to chance, food and beverage manufacturers must employ many tools to ensure their people, plants, products and bottom lines are protected.

didn’t plan it this way, but when we were putting the final touches on this issue, a definite theme emerged. Some of the topics we are covering this month include new request for proposal (RFP) guidelines, a factory acceptance testing (FAT) opinion piece from Impossible Foods and the 10 commandments for CIP design, all from PMMI’s OpX Leadership Network; machine safety; pest control; and sanitary plant design. In the food and beverage industry, the word “risk” often connotates issues such as supplier certification problems, not following GMPs properly or managing disgruntled employees. Today, risk is not only in your supply chain, but in your plant layout and design, and the equipment you specify. When I visited the new Dairy Farmers of America (DFA) facility in Garden City, Kansas, a few months ago, I was struck by the stringent food safety measures this highly automated plant has in place. This was the very first food facility I visited where visitors must don additional booties, hair nets and jumpsuits — when moving between zones — on top of their primary food safety apparel. DFA is leaving nothing to chance, and their customers require this level of attention to hygiene. See the cover story about DFA’s Garden City facility beginning on Page 21 in this issue. Other parts of this issue focus on how food and beverage manufacturers can work with machine builders to mitigate risk by creating detailed RFPs for capital equipment and assessing machine hazards during a line integration project. Sanitary plant design also requires a proactive approach. Insulated metal wall and ceiling panels, controlled airflow, linear line flows, and reducing downtime with quick and effective cleaning are standard requirements for modern food processing plants. But equipment specifications from the original RFP up to the final FAT are also essential to mitigate risk, whether that risk is food safety, staff safety or protecting the bottom line with efficient production. PFW

PROFOOD WORLD EDITORIAL ADVISORY BOARD CHRISTINE BENSE

CHIEF OPERATING OFFICER Ventura Coastal

HENDRIK EYSELEE

DIRECTOR OF ENGINEERING, CHEESE AND DAIRY

The Kraft Heinz Company

GREG FLICKINGER

GROUP VICE PRESIDENT OF MANUFACTURING OPERATIONS H-E-B | Manufacturing

BILL GILL

ASSISTANT VP, ENVIRONMENTAL AFFAIRS Smithfield Foods

JOHN HILKER

SENIOR VP, MANUFACTURING The C.F. Sauer Company

VINCE NASTI

VP, OPERATIONS

Nation Pizza & Foods

JIM PRUNESTI

VP, GLOBAL ENGINEERING Campbell Soup Company

TONY VANDENOEVER DIRECTOR, SUPPLY CHAIN ENGINEERING PepsiCo

DIANE WOLF

INDUSTRY CONSULTANT, FORMER VP OF ENGINEERING AND OPERATIONS Kraft Foods

JOE ZEMBAS

DIRECTOR, ENGINEERING AND TECHNICAL SERVICES The J.M. Smucker Company

JOYCE FASSL EDITOR-IN-CHIEF jfassl@pmmimediagroup.com Follow us on Twitter @ProFoodWorld

ProFood World

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June 2018

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NEWS

IN THE

RFP GUIDELINES DELIVER CAPITAL PROJECT EXCELLENCE

MMI’S OPX LEADERSHIP NETWORK’S Capital Projects Solutions Group was formed to enhance communication among all stakeholders during commercial transactions involving capital equipment. The group’s objective is to achieve capital project excellence, minimize costly misunderstanding, and provide documents that adhere to good standard business practices and are fair to both parties. “Detailed requests for proposals (RFPs) enable greater clarity of project requirements in commercial transactions involving capital equipment,” states Stephen Perry, managing director of the OpX Leadership Network. For consumer packaged goods (CPG) companies, achieving vertical startups of packaging and processing equipment lines consistently and effectively are paramount. The new RFP Process Template for CPG Industry from the OpX Leadership Network provides greater understanding of project requirements, which results in better outcomes for all stakeholders involved in the process. The level of detail and support required when using this template depends on the CPG’s business procedures and the complexity of the capital project. When using the template, CPGs should provide the bidder with a high-level abstract of the project, requirements, purpose and a detailed timeline. In addition, information such as insurance requirements, technical and validation specifications, special contract needs, site drawings, and safety standards should be included in the template. This information can be included in steps one to four of the RFP template. (See diagram on this page.) More specific machinery requirements, product descriptions and expected machine performance levels are indicated in steps five through seven. Here, CPGs provide the quality, rate, validation and performance requirements as measured and acknowledged by the plant or facility operations team that will allow final payment and RFP Process Template contract fulfillment criteria to be for CPG Industry The document provides seven key steps met by the equipment supplier. for collaboration among stakeholders “Total cost of ownership in developing a robust RFP: (TCO) is a foundational element of RFP and capital projects Invitation to participate. excellence as it illuminates true equipment costs by focusing in Company information. detail on both acquisition and operating costs,” notes Perry. Instructions and schedule to meet RFP. “It’s a move away from a ‘price only’ approach to a more holistic Documents summary. ‘life cycle’ one to capital spend.” To download a copy of the Project introduction – equipment. RFP Process Template for CPG Industry as well as the supportProduct and package description. ing RFP Checklist, visit www.opx leadershipnetwork.org. Other helpful tools at this site supportPerformance success criteria. ing the RFP process include the Source: PMMI’s OpX Leadership Network. TCO Playbook and Checklists.

1 2 3 4 5 6 7

Changes at the top for Campbell’s Following the decision of President and CEO Denise M. Morrison to retire on May 18, Campbell Soup Company named Keith R. McLoughlin, a Campbell board member since 2016, to serve as interim CEO. McLoughlin will remain on the board. Prior to joining Campbell, McLoughlin was president and CEO of Electrolux AB. Effective June 4, the company named Roberto Leopardi as president, Campbell Meals & Beverages, a division that includes its North American soup, sauces and shelfstable beverage brands, as well as Pacific Foods and Plum. Leopardi will report to COO Luca Mignini.

Emerson is buying Aventics Emerson will pay $622 million to purchase Aventics, a manufacturer of pneumatic components and systems, from Triton. Germany-based Aventics has approximately 2,100 employees globally and five manufacturing locations.

Labor issues remain a pain point for beverage industry According to Beverage Trends in Packaging and Processing Operations, a new report by PMMI Business Intelligence, many respondents report severe shortages of operators, mechanics and temporary workers, at least in some geographic areas. Respondents cited issues such as filling an open position, only to have employees leave after being fully trained; or having great difficulty finding temporary employees. Some respondents believe their labor challenges are exacerbated by the 12-hour shifts commonly used in 24/7 production environments. Worn-out production employees can have a significant impact on a plant’s overall productivity and contribute to a high turnover rate. Download the free report at https://bit.ly/2GLoMgJ.

www.profoodworld.com

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June 2018

ProFood World

5/30/18 10:32 AM

IN THE NEWS

PROFOOD TECH GEARS UP FOR 2019 RETURN

HE U.S. MARKET for food and beverage processing machinery projects to break the $6 billion barrier, reaching $6.1 billion by 2021, according to the 2018 Global Trends Food and Beverage Processing Report by PMMI, The Association for Packaging and Processing Technologies. To address this demand, ProFood Tech (March 2628, 2019, McCormick Place, Chicago) is the only processing trade show in North America that transcends market sectors, welcoming 7,000 professionals from all food and beverage processing markets. Produced by PACK EXPO, Anuga and the International Dairy Foods Association (IDFA), the three-day event showcases cutting-edge crossover technologies and innovative solutions

from 450 exhibitors. Nearly two-thirds of the food and beverage professionals who visit ProFood Tech have significant or final buying power. “The success of the inaugural ProFood Tech 2017 confirmed our belief that the industry craved an all-inclusive, onestop shop for their food and beverage processing needs,” says Jim Pittas, president and CEO of PMMI. More than just a trade show, ProFood Tech convenes the entire food and beverage processing industry with worldclass educational offerings, networking receptions and industry award ceremonies. The ProFood Tech Conference, produced by IDFA, offers educational experiences covering regulations and food safety, consumer trends and marketing,

food processing advances and technology, as well as business and leadership development. Additionally, ProFood Tech will welcome the Packaging & Processing Women’s Leadership Network, Emerging Leaders Network, Cold Pressure Council, Manufacturing Innovation Awards, and Sustainability Excellence in Manufacturing Awards. Since ProFood Tech occurs biennially, the ProFood Live conference debuts June 20-21, 2018, in Chicago. This bridge between show years presents the collective industry expertise of ProFood World magazine, providing real-world solutions in manufacturing, automation and sustainability. To learn more, visit www.profood tech.com. PFW

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YD DU UT TS SACCEPTANCE ES SA AC C Y D U T S E S A C OPX INTEL: FACTORY Y E TESTS

CONDUCTING FATs IS MORE ESSENTIAL THAN EVER The more complex or custom the project or situation, the greater the value it will derive from an in-depth review of the FAT protocol. ROY GREENGRASS DIRECTOR OF MANUFACTURING ENGINEERING, IMPOSSIBLE FOODS

HE CONSUMER PACKAGED GOODS (CPG) and food manufacturing industries are under more pressure than ever to respond to business demands, such as: • Increased capacity. • Speed to market. • New technology introduction. • Making more with less. • Leveraging capital budgets. In this ever-tightening, resource-constrained environment, why is it more essential than ever to properly plan for and execute factory acceptance tests (FATs)? Don’t FATs cost extra time, money and product waste? Isn’t my contract with the OEM or my design firm going to assure me that the new equipment works? Unfortunately, the reality is the absence of an FAT or a poorly prepared one can significantly delay a startup, increase costs and cause numerous ongoing operational issues. Significant time and expertise is lost when issues arise on the job site when technical solutions or quality cannot be easily fixed at the factory. Another factor is that most contracts specify that passing an FAT is a criterion for payment. Purchase orders or contract terms are derived from the functional requirement document. It is important that this test be witnessed by a technically competent project manager with operational knowledge or owner representative to ensure compliance. Being part of an entrepreneurial startup company is exciting, challenging, invigorating and, at times, overwhelming. Impossible Foods is an innovative food technology company with a strong scientific and manufacturing knowledge base. However, limited staff resources or time constraints to meet project timelines does not mean FATs should be avoided to execute a project more quickly. Just as there are protocols for proving a science or experimental thesis, it is also important to use similar due diligence for the factory acceptance process. I participated on the OpX Leadership Network team that published the document “One Voice Factory

Acceptance Tests: Protocols for Capital Equipment in the CPG Industry” in late 2015. I can attest to the value of FATs. When properly planned and executed, FATs provide benefits that far outweigh the costs. Two overriding benefits are vertical startups and sustainable operational reliability.

It all adds up Do the math on vertical startups. How much would it mean to your business to give back an extra week or two in production? Most managers agree there are ways that you can significantly compress the traditional ramp-up time of a new production line without increasing the size of your team or suppliers’ workloads. Consider how much cost is associated to wasted on-site labor. Startups are the tip of the iceberg. The reoccurring value is earned through sustainable operational reliability. You can use the OpX Total Cost of

Impossible Foods is a Silicon Valleybased company known for the plantbased Impossible Burger. The company’s mission is to make the global food system more sustainable. The company aims to give people the taste and nutritional benefits of meat in a plant-based product. Photo courtesy of Impossible Foods.

www.profoodworld.com

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June 2018

ProFood World

5/30/18 10:34 AM

OPX INTEL: FACTORY ACCEPTANCE TESTS

| TC12-02USA |

Ownership model and Overall Operational Effectiveness Benefit Calculator to assist you in quantifying this benefit to the business. Engagement of the workforce (also an OpX best practice) begins this positive cycle of sustainable operational reliability. FATs are terrific opportunities to engage the many different stakeholders impacted when bringing in a new manufac-

System-integrated IIoT with standard PC-based control

www.beckhoff.us/Industrie40 Beckhoff provides the ideal foundational technologies for Industrie 4.0 and Internet of Things (IoT) applications via standard PC-based control. With the TwinCAT engineering and control software, machine control systems can be extended to support big data applications, cloud communication, predictive maintenance, as well as comprehensive analytical functions to increase production efficiency. As a system-integrated solution, TwinCAT IoT supports standardized protocols for cloud communication and enables the easy integration of cloud services right from the machine engineering stage. In addition to fault analysis and predictive maintenance, TwinCAT Analytics offers numerous opportunities to optimize machines and systems in terms of energy consumption and process sequences.

turing line. Soliciting opinions and concerns during the design phase, providing hands-on experience during the FAT, training in operational nuances, and participating in the new equipment installation process will create a sense of ownership. First and foremost, the FAT protocol is a tool to engage in a dialogue with key stakeholders. Typical questions should include: • What is critical to ensure the project’s success? • What does purchasing, operations, engineering or maintenance need? • What does the OEM need, and when does it need it? During my career, I have led numerous FATs. Some more successful than others. Failures were often due to rushed fabrication with incomplete checkouts by the vendor. The OpX tool on FATs is beneficial to both the CPG company and equipment vendor. When I arrived at Impossible Foods, a major project was just completed by a design-build firm with an FAT on major equipment. The complex project of starting a new production line was successfully implemented. My role in the organization is to expand this production capability to other sites to meet our growing demand. I ensure proprietary designs are properly developed, operational technology is utilized, and the FAT protocols and the many other OpX best practices are systemically applied. According to Steve Schlegel, managing director of PMMI’s OpX Leadership Network, “CPGs adopting the OpX best practices in their business will reap the benefits of accelerated business results.” You may wonder if the FAT protocol document is needed on every project. The answer is no, but the process is. The more complex or custom the project or situation, the greater the value is derived from an in-depth review of the FAT protocol. For a more standard purchase with little risk to your startup, the team may decide that doing an FAT via FaceTime or video is all that is required to certify that you will receive what you have purchased. The importance of user acceptance testing is essential to the successful implementation of your project. Usually all staff are stretched to the limit during a startup. Following the FAT process will avoid additional coordination and time spent on solving equipment startup issues. In the resourceconstrained world of capital expenditures, using both the FAT process and OpX best practices can significantly increase your project’s success. For more information, visit www.opxleadership network.org. PFW 14

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ProFood World

June 2018

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PACKAGING TECHNOLOGY

NATURAL PAIRING Penn State uses crab shells and wood to create an inexpensive, eco-friendly biomaterial that it touts as a sustainable alternative to plastic packaging that could reduce pollution. MAYA NORRIS MANAGING EDITOR

RAB SHELLS AND WOOD have more in common than one might assume. Researchers at Penn State University are using these readily available, natural items to create an inexpensive, ecofriendly biomaterial that they say can be used to replace petroleum-based plastic packaging while significantly reducing pollution. This new biodegradable barrier coating that the Penn State researchers developed is composed of equal parts treated cellulose pulp (carboxymethyl cellulose) and chitosan — both abundant, economical and compostable materials. Cellulose pulp comes from wood or cotton, while chitosan is derived from chitin, the main component found in the exoskeletons of arthropods and crustaceans, such as lobsters, crabs and shrimp. Using an aqueous buffer, both materials are blended at an ultra-high shear rate to create a polysaccharide polyelectrolyte complex. The different molecular charges of chitosan (a cationic positive charge) and carboxymethyl cellulose (an anionic negative charge) lock together and electrostatically bond to create the foundation for an impervious film and adhesive.

High performance The Penn State researchers found that this polysaccharide polyelectrolyte complex performed well during the research trials. Paperboard coated in the biomaterial demonstrated strong oil, vapor and water barrier properties. It also proved to be resistant to salt, toluene and heptane. “It meets TAPPI T 559, the industrial standard for grease resistance,” says lead researcher Jeffrey Catchmark, professor of agricultural and biological engineering at Penn State’s College of Agricultural Sciences. “It resists oil and aqueous water-based solutions at a pH from at least three to nine, which is important for the food industry.” In addition to coating a variety of food packaging surfaces, the biomaterial is also suitable as an adhesive for packaging. “If you use the formulation to bind two surfaces, it simply acts as an adhesive,” Catchmark says. “It’s remarkable.” “This is essential in packaging because it’s not just the ability to have a surface be the barrier. You also want to be able to make more complex products,” he

adds. “You want to make clamshell packages and cups that require an adhesive to adhere the paperboard surfaces to make the final product. Our new biomaterial acts as both the coating and the adhesive.”

Environmental impact With its robust barrier properties and biodegradability, the biomaterial could replace millions of tons of petroleum-based plastic in food packaging globally and substantially decrease plastic pollution, Catchmark says. “I’m very interested in trying to make an impact in the world by getting this technology into products so that we can reduce pollution,” explains Catchmark, who has spent the last decade researching and developing sustainable materials that could serve as viable alternatives to synthetic materials like Styrofoam and PET. “Essentially plastic and other chemical pollution are creating problems in our ecosystem. Plastic is a very significant problem that we have right now.” According to a 2017 research study published by the University of Georgia, University of California at Santa Barbara and Sea Education Association in the journal Science Advances, more than 400 million metric tons of plastic were produced globally in 2015. The researchers found that about 91 percent of plastic isn’t

Lead researcher Jeffrey Catchmark and his team at Penn State University spent six years developing a biomaterial coating and adhesive as a sustainable and affordable alternative to plastic packaging. Photo courtesy of Penn State University.

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PACKAGING TECHNOLOGY

recycled, with 79 percent finding its way into landfills and the natural environment. The largest market for plastic is packaging, which has accelerated the global growth of plastic as consumers shift from reusable to single-use containers, according to the study. If current plastic production and waste management trends continue, the researchers predicted that about 12 billion metric tons of plastic waste will accumulate in landfills and the natural environment by 2050.

Protecting the bottom line While most people acknowledge plastic pollution is a growing and serious issue, Catchmark recognized that the problem wouldn’t be enough to persuade food and beverage companies to try a sustainable alternative to plastic. That’s why the Penn State team specifically experimented with economical, accessible industrial materials like chitosan and cellulose that wouldn’t hurt food and beverage companies’ bottom line. Because all plants make cellulose, it is one of the most abundant, inexpensive organic compounds on Earth. It’s just as easy and affordable to obtain chitosan as well because it is a byproduct of the shellfish industry. According to the Food and Agriculture Organization of the United Nations, every year 6 million to 8 million tons of waste

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crab, shrimp and lobster shells are discarded. Instead of tossing them, these waste shells could be recycled to create the biomaterial Penn State developed. “Cellulose and chitosan are the highest volume, lowest-cost, biologically-derived polymers out there,” Catchmark says. “Our invention leverages something that is already made in huge quantities. These polysaccharides are among the cheapest, sustainable, ecologically compatible, compostable materials that exist in nature. It may be the only solution out there that offers this kind of barrier performance at a cost point that can potentially beat plastic.” After six years of working on this biomaterial coating and adhesive, Penn State is seeking a patent for it and collaborating with some paper, food and beverage manufacturers and packaging companies to bring it to market. Catchmark expects the biomaterial to make its mark in the industry and the environment. “It’s a disruptive technology,” he says. “People have explored polysaccharides for a long time and have not seen this kind of performance before. We’ve created a very manageable solution. It’s something that is manufacturable, easy to produce, very cost effective and good for the environment. It’s a win across the board.” PFW

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F B A

FLEXIBLE PACKAGING BOOST IN AFRICA AND MIDDLE EAST

Volume share of packaging types in the Middle East and Africa - 2015

HE IMPROVING ECONOMIES of the Middle East and Africa bode well for packaging growth in those regions, especially flexible plastic packaging for ready-made foods, according to the 2017 Global Packaging Trends report from Euromonitor International and PMMI, The Association for Packaging and Processing Technologies. The report forecasts a 5.3 percent compound annual growth rate (CAGR) in packaging from 2015 to 2020. While packaging growth is increasing overall, flexible plastic packaging is expected to grow at a 5.7 percent CAGR in the forecast period. Flexible packaging is popular in developing countries because it meets the demand for packaged foods, according to the report. As cities in the Middle East and Africa urbanize, more residents are purchasing packaged foods from new supermarkets and retail shops instead of raw foods from traditional roadside markets. In addition, more women in these countries are entering the workforce. With dual-income households on the rise coupled with the busy lifestyles of people in these households, many families are willing to pay more for the convenience of single-serve and packaged foods. PFW To read the 2017 Global Packaging Trends report, please visit www. pmmi.org/business-intelligence.

Folding Carton 6% Thin-Wall Plastic Container 7%

Others 34%

163.3 PET Bottle 13%

billion units sold in 2015

Glass Bottle 12% Total 2015 market size Total 2020 market size Forecast CAGR (2015 - 2020)

Flexible Plastic 28% 163 211 5.3%

Source: 2017 Global Packaging Trends produced by Euromonitor International and PMMI, The Association for Packaging and Processing Technologies.

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DAIRY FARMERS OF AMERICA REACHES FOR THE SKY A world-class milk drying facility in Garden City, Kansas, uses redundant systems and advanced automation systems to keep its processes running 24/7. JOYCE FASSL EDITOR-IN-CHIEF

HAVE WITNESSED THE PINNACLE OF automated food processing plants, and it might surprise you that it is located in an unassuming, quiet corner of southwest Kansas. The Dairy Farmers of America (DFA) greenfield milk drying facility is strategically located in Garden City, Kansas, close to farms with more than 80,000 milking cows. As drivers enter Garden City, they can’t miss the building holding the largest single whole milk dryer in North America at this new state-of-the-art facility, now part of DFA’s more than 40 manufacturing facilities nationwide. The DFA cooperative has more than 14,500 members in 48 states that produce approximately 23 percent of the milk in the United States from more than 2 million cows. Along with its fresh and shelf-stable fluid milk products, DFA produces cheese, butter, dried milk powder and other dairy products. Dairy Farmers of America’s new 267,000-sq-ft facility in Garden City, Kansas, sits on 165 acres and stands 157 ft tall. Designed to run 24/7, the facility can receive up to 84 5,000gal milk tankers from local farms per day. Photo by Katina Reist Photography.

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MANUFACTURING INNOVATOR OF THE YEAR

“We want to focus on being the best whole milk powder plant, on what we put into the design, the shelf life of the product, the quality of the product, just everything about it,” says Wesley Clark, director of operations at the Dairy Farmers of America’s Garden City plant. Photo by Katina Reist Photography.

Before DFA arrived on the scene in Garden City, the land where the new plant stands today was a waterdeprived cornfield. Now, the 267,000-sq-ft facility sits on 165 acres and stands 157 ft tall. Designed to run 24/7, the facility can receive up to 84 5,000-gal milk tankers from local farms per day and has storage for 4.1 million lb of milk, 350,000 gal of process water and 240,000 gal of pasteurized cream. The plant can produce up to 7,000 25-kg bags of low-spore milk powder per day. According to Wesley Clark, director of operations for DFA’s Garden City facility, “Our core focus is to bring value to the member/farmer owner members. They are a key strategic initiative for the cooperative.” Through its commercial investments, DFA continues to provide a strong and stable milk market for its dairy farmer owners, he adds. The Garden City location provides a home for local DFA members’ milk, which was previously transported to other states, such as New Mexico or Colorado, says Clark. Building a strategically located new plant has allowed DFA to reduce long-haul transportation. Now, farmer/members can move the milk out of the farms quickly. “It gives them more opportunity, and the cost of the transportation is really driven down,” states Clark. “It really helps the quality of the milk. We’re talking five hours on the road minimum.” The facility in Garden City produces instant agglomerated whole milk powder, instant skim milk powder, 22

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26 percent fat-filled whole milk powder, 28 percent fat-filled whole milk powder, medium-heat whole milk powder and nonfat dry milk. Sold to a vast array of food and beverage processors in the United States, Latin America and Asia, these dry milk products are packed in 25-kg bags and various tote sizes.

Best-in-class technology After DFA decided on the Garden City location, it sought a partner to build its world-class milk drying facility. “We needed a gatekeeper with a strong sense of ownership,” Clark says. “We wanted assurances that what we say we want today gets done tomorrow.” Shambaugh & Son met DFA’s stringent requirements as a one-stop shop that provides turnkey operations. Working with its long-time architectural partner MSKTD & Associates and building shell contractor McCarthy Building Companies, Shambaugh & Son began construction in September 2015. According to Alan Low, Shambaugh & Son’s senior vice president and project manager, “Building a food manufacturing facility correctly is always challenging, but a plant where individual pieces of equipment span from the ground level, through floors and to the ceiling over 150 ft above them is a whole different kind of mind set.” One of the biggest challenges was coordinating structurally sound sections of the building to be erected to support intermittent major equipment set-

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Congratulations

on winning the Manufacturing Innovation Award!

The architects, engineers, and interior designers of our Food Processing Group were excited to deliver the DFA facility in Garden City, Kansas. That excitement continues today with DFA winning the Manufacturing Innovation Award! Advances in processing technology and manufacturing are important factors in productivity; however people are the primary factor responsible for the success of any venture, and our success is because of our people. ~ George Bachnivsky, Vice President

WE are MSKTD!

Celebrating Years

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MANUFACTURING INNOVATOR OF THE YEAR

ting, while other sections of the building could be completed around them. “I specifically remember the day we lifted the 138,000-lb dryer cone to 157 ft above the ground to drop it down into the building to rest on the 72-ft elevation concrete floor with the opening only 6 in. larger than the 38-ft diameter cone. It made me appreciate how valuable 3-D modeling really is,” Low recalls. In addition to the world-class dryer from Tetra Pak, the facility prides itself on high levels of hygienic design. “We’ve got HEPA-filtered air throughout the areas three, two and one in the plant, which means clean floors, clean walls, clean environment, cleaner than most homes,” Clark explains. This dryer has all its air HEPA filtered, and the air environment around the shaking beds are all HEPA filtered. The air system also handles positive control between departments. “If I’m in packaging, I want positive air. I don’t want anything being pulled into that area. I want to be blowing stuff out,” Clark says. Quality and efficiency are paramount to DFA, and it shows in the depth of the machinery on site. The plant does not ever shut down for cleaning. Its state-of-the-art equipment allows it to run and clean continuously 24 hours a day. “We’ve got dual pasteurization plates that get changed every 10 hours. We’ve got three evaporators that get changed every 20 hours. We’ve got separators that are rotated out every 10 hours, and each one is washed every 10 hours. All these things lead up to the quality in the finished product,” states Clark. Running four Tetra Pak separators and three Tetra Pak evaporators is a tall task, but advanced automation and controls allow only two employees to run the evaporators, silo, wet process and lactose blending. The facility’s production of milk powders 24/7 for more than 20 consecutive days is unique in the United States and represents a major improvement in overall equipment effectiveness. 24

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ABOVE: The 240 Alfa Laval mixproof valve matrices at the plant consistently control uninterrupted product flow to critical process systems. Photo by Katina Reist Photography. LEFT: The Dairy Farmers of America’s Garden City facility houses the largest whole milk dryer in North America. Photo by Katina Reist Photography.

Designing a downstream dryer feed system with rotating evaporators that clean independently during production with a dual high-pressure feed line, highpressure lance production and a clean-in-place (CIP) management system for this complex project required the development of a much higher level of

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economizers that provide heating to the utility rooms during cold months. The plant’s compressed air is supplied by a system of efficient rotary screw compressors with the capacity to provide a total of 3,100 cu ft of air per minute, as needed. Each individual compressor is uniquely cooled by the central refrigeration and equipped with specially designed exhaust and supply air ducting that allows for the automated recovery of compressor heat, zero-loss pneumatic condensate drains, a condensate separator for lubricant recovery and stainless-steel distribution to maintain the plant’s hygienic requirements. The plant’s water treatment system is divided into separate distribution networks for treated, domestic and soft water, allowing each stream to be independently managed to prevent overuse. Shambaugh’s engineering team decided to use a centralized ammonia system design. In order to minimize the refrigerant charge and conform to EPA- and OSHA-mandated regulatory requirements, a safe secondary cooling medium of propylene glycol was used to distribute cooling to the process areas beyond the

HMI applications were deployed throughout the plant. An APC Thin Management software platform allows for centralized deployment to multiple devices. Photo by Katina Reist Photography.

automation than any of DFA’s other milk powder manufacturing facilities, says Low. “The ability to bring systems on and off production for cleaning, while maintaining a constant process rate through each, necessitated employing different design approaches and equipment,” Low states. Typically, mix-proof valves offer the ability to switch from production to CIP and back without manual intervention. This approach, however, needed to be expanded to allow the ability to bring systems online and offline and, at the same time, feed the same equipment or different equipment without a production interruption. More than 240 Alfa Laval mix-proof valves meet this challenge at the Garden City plant.

Plant infrastructure The backbone of the facility is the infrastructure of the mechanical systems. Steam, compressed air, HVAC and incoming water treatment can be substantial energy wasters if not designed and integrated properly and can contribute to outside contamination if they underperform or fail. The plant steam supply is generated by efficient natural gas-fired tube boilers that can provide up to 161,000 lb of steam per hour as needed. Each individual boiler is sequenced by the central control system to supply the exact amount of steam supply for any given demand, with an 8:1 turndown rate utilizing variable speed drives, oxygen trimming, flue gas recirculation, low-emission nitric oxide, nitrogen dioxide burners to reduce the carbon footprint, and internal stack energy 26

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Multiple cold milk separators supplied by Tetra Pak enhance final milk powder properties and allow for 24/7 production. Photo by Katina Reist Photography.

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Technopak congratulates Dairy Farmers of America 2018 Manufacturing Innovation Award Winner Technopak designs, manufactures and installs hygienic 25kg bag filling and packing lines for the dairy, infant formula, nutrition and pharmaceutical industries. Our experienced team is proud to play a role in the success of DFA and we will remain dedicated to providing the best possible solutions for all our customers. Look to us for a complete turnkey system or component to improve your powder packing system. Hygienic Bag Filling Systems Inert Gas/Modified Atmosphere Packing Automated Powder Sampling Systems Reject Stations Inkjet Coders Tamper Evident Seals - AsurasealÂŽ

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A sustainable and energy-efficient process

ARDEN CITY, KANSAS’ WASTEWATER treatment facility did not have the capacity to handle the projected biological load generated by a large milk processing plant. In fact, the municipality was already facing increased demand for quality water for agricultural and industrial use. Dairy Farmers of America (DFA) agreed to build a 2.5-million-gal, usespecific wastewater treatment plant using membrane bioactivity and UV disinfection that would successfully combine the plant’s properly treated effluent discharge with the city’s effluent at a shared outfall storage system. This arrangement allows Garden City to provide the combined effluent for the area’s muchneeded agricultural irrigation. Reducing the dependence on the water supply from the municipal water system by continuously capturing available reusable water produced from the 24/7 operation at DFA was of paramount importance, says Alan Low, Shambaugh & Son’s senior vice president and project manager. “Process water push valve arrangements were designed for the entire liquid process portion of the plant. This allows every product transfer, to and from silos, to and from process systems, and to and from intermediate work in progress, to be captured for reintroduction into the process system,” states Low. When evaporators are brought online and taken offline, it causes initial product concentrate that is low in solids and results in unsellable product that not only wastes energy to produce, but is typically sent to landfills. “To address this waste issue, product recovery tanks were designed to store the lower

solids produced by the evaporators during startup, when building solids and during shutdown as water is pushed through the evaporator to clear product from the evaporator,” Low says. Recovery tanks were sized to handle the volumes produced during these times and allow for the re-blending of the product back into the evaporation process. Back at the processing plant, infrastructure systems were equipped with every possible key component: • High-efficiency motors. • Variable speed drives. • Heat rejection recovery to use for environmental media and water heating. • Seasonally adjustable variable air volume control. • Low-emission burners. • Individual component pressure controls for instantaneous modulation reaction. • Power metering data transfer to the manufacturing execution system. • LED lighting. “Air control in the plant is part of our energy efficiency,” states Clark, “[although] we do consume some of the building air for intake on our feed to our dryer inlet filters.” When it’s really cold outside, the system uses some of the building heat to preheat the air going into the dryer. “We’re always looking for ideas to save energy,” adds Clark. “The plant is designed to utilize the energy that is available to reduce cost. The energy is found in the incoming cold milk and regenerated into a valuable source of energy to reduce cooling cost on site.”

A 2.5-million-gal per-day, on-site wastewater treatment system purifies the plant discharge and returns it to Garden City as agricultural irrigation quality water. Photo courtesy of Shambaugh & Son.

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confinements of the refrigeration system utility area. The system was further enhanced with the use of variable frequency drive motors and a centralized control system for precise temperature control.

Complex automation system Designing an automation system to manage all the complexities associated with downtime prevention and safeguarding for potentially unstable power, the automation team looked for a solution that would be fault tolerant. Rockwellâ&#x20AC;&#x2122;s PlantPAx was chosen as the automation platform to provide a distributed control system built on a common Rockwell Automation platform using standard library objects. Human machine interface (HMI) applications were deployed throughout the plant via the use of an APC ThinManager software platform that allows for centralized deployment to multiple devices. A centralized, plantwide uninterruptable power supply ensures the automation system continues to function through power surges, outages and brownouts. The plantwide Each day, up to 7,000 25-kg bags of quality milk powder can be produced. Photo by Katina Reist Photography.

Ethernet network ties the plant floor and the office environment together. This allows for the real-time monitoring and management of production activities. Dual high-pressure pumps allow the plant to run 24/7. With them, the plant does not have to shut down the dryer, and the temperature swings that occur when starting up the dryer are eliminated. â&#x20AC;&#x153;In this case, we can switch to the other pump without disturbing the dryer. The quality of the powder is improved with the consistency of the temperature. Because of the pump switching and the smoothness of how we can bring a pump online, it keeps the nozzles clean and really improves the quality of the finished product,â&#x20AC;? Clark adds.

Addressing biosecurity The raw milk receiving area poses one of the biggest risks to the biosecurity of a dairy processing plant. Potential contamination can come from nonpasteurized milk, milk tankers, receiving personnel and the dairy farm itself. To prevent cross-contamination, receiving personnel enter the plant through a different employee welfare and locker room area from the main plant staff. In the event of a required management or maintenance interaction in the receiving area, this staff cannot access the receiving area from the main plant; they enter from the receiving personnel locker area, after putting on additional personal sanitation protection equipment. Space is also allocated for the storage of equipment, spare parts and maintenance repair tools used in the receiving area, further reducing

A flexible cow water removal system uses three independently cleaned rotating evaporators to produce high-quality milk powder 24/7. Photo by Katina Reist Photography.

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MANUFACTURING INNOVATOR OF THE YEAR

The utility infrastructure is isolated within a large utilidor to provide service to the entire plant. It can only be accessed from the maintenance personnel area. Photo courtesy of Shambaugh & Son.

potential contamination from the receiving area to the main plant. Other stringent facility hygiene features focus on plant attire in the strict work zones. On the plant floor, each employee must wear a uniform and boots in the pasteurized wet floor zone. The dryer area is protected with a key card entry. If employees need to enter the dryer area, they must don special booties. In order to enter the packaging area, workers must put on a jumpsuit over their uniform and wear special packaging room shoes. “Just because we’re in the wet zone with our boots and our uniforms on doesn’t mean we’re protected,” declares Clark. “If we get water on our feet, then we’ve created a problem. Those boots are controlled, and they’re only kept in area three for area three.” A viewing corridor was installed to allow visitors to observe the process plant without entering the

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It’s all about the people The plant’s headcount is currently 66 people, quite a feat for a 285,000-sq-ft facility running 4 million pounds of milk. DFA recruited nearly all of its hourly workforce locally. Garden City Community College helped with food safety and electrical training programs before the plant started up. “It’s getting harder and harder to find qualified people, regardless of the location,” Clark says. “But a brand-new state-of-theart plant can be an enticement.” Alan McEntee, DFA program manager for the Garden City project, worked directly with Shambaugh and says the cooperation of the owners, contractors, and local and state authorities made the project a success.

Many process areas in the plant are considered wet and washdown spaces. For this reason, the power and control conduits were designed to meet up with their equipment from underground, limiting penetration above. Photo by Katina Reist Photography.

hygienically controlled areas of the plant. If an outside individual must enter the plant, a separate red-line area provides appropriate outerwear covers and sanitizing stations. Another unique hygienic design feature is how the plant has been set up for the drying and evaporation operations to communicate and work together. “We have dryer operators in the control room, but there’s a countertop between them and the wet zone staff. There’s a clean cutoff between them, so they can still work together,” Clark explains. “They’re both in the same area, but in different zones.” In addition to robust food safety management and HACCP plans, the facility features an on-site certified lab. It also obtained USDA approval prior to startup and has CNCA certification for shipping to Asia, as well as KDA approval for Grade A status on its cream.

June 2018

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“I would say the best thing is that the project started on time,” as Clark recalls that day in November 2017. “The first load of milk that came in over the scale — that was really neat! Being able to add value to a plant of that size, with a product that’s not very developed in the United States — an instant whole milk powder — it was a really good experience,” he concludes. PFW Alfa Laval www.alfalaval.com

The plant’s ammonia system employs four Frick compressors. One of the units has a variable speed drive to ensure closeset point suction control, providing precise glycol temperature control for the process cooling loads. Photo courtesy of Shambaugh & Son.

Frick www.frickrefrigeration.com Rockwell Automation www.rockwellautomation.com Technopak www.technopak.co.nz Tetra Pak www.tetrapak.com Shambaugh & Son www.shambaugh.com

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SANITARY PLANT DESIGN

MANAGING YOUR RISK

A well-developed sanitary plant design takes a proactive approach to keeping pathogens and contamination at bay. MAYA NORRIS MANAGING EDITOR

HE RECENT E. COLI OUTBREAK with romaine lettuce was a stern reminder to food and beverage processors that food safety should always be their top priority. A recall is not only detrimental to public health, but can also have devastating consequences to a company’s profits and trust with its consumers. The best way for food and beverage manufacturers to avoid recalls and keep their products safe is to create a sanitary plant design that prevents and eliminates hygienic hazards before they can contaminate products and create public outbreaks of foodborne illness. “It’s a fundamental piece of any food facility because if you don’t have sanitary design, you’re really exposing yourself as a business owner. It mitigates the chances of recalls, contamination, and possibly worse ramifications,” says John Koury, director of design for A M King, a Charlotte, North Carolina-based architecture and engineering firm. “Sanitary design permeates just about every design decision you make in the process.” “It’s about managing risk, knowing what our clients’ critical control points are, and then managing to eliminate as much risk as possible in reducing any kind of contamination,” says Rick Elyar, business manager for food and beverage at HANSEN-RICE, INC., a Nampa, Idaho-based design-build firm. An effective sanitary plant design prevents pathogens from infiltrating the facility and tainting products while still ensuring the plant is productive and can be cleaned down to a bacteriological level. Engineering consulting firms typically create sanitary plant designs based on sanitation guidelines from a variety of sources, including the 3-A Sanitary Standards, BISSC (Baking Industry Sanitation Standards Committee) standards, Hazard Analysis and Critical Control Points (HACCP) and Hazard Analysis and Risk-Based Preventive Controls (HARPC) techniques, and, most notably, the North American Meat Institute sanitary design principles. But no matter what criteria they use, most sanitary design plans center on three broad principles: creating zones of separation and control in

Many food and beverage companies install insulated metal panels (IMP) for the walls and ceilings of their plants. IMP panels are resistant to bacteria, easily washed down and can withstand harsh cleaning chemicals. Photo courtesy of HANSEN-RICE, INC.

the plant, controlling temperature and moisture, and ensuring the facility and its equipment are easy to clean and maintain.

Safe zones When developing a sanitary design plan for a food and beverage plant, engineering firms recommend creating distinct hygienic zones that control the movement of products and people, often considered the biggest threat to food safety in a plant. It includes separating production areas with physical barriers to prevent contaminants from migrating from one area to another, particularly those at high risk for cross-contamination. For example, a plant should house the area that processes raw, uncooked food in a room separate from the area that processes and packages the finished, ready-to-eat product. “The goal is to assure the end user a safe product, and the goal would be to do it in an operationally efficient manner,” says Joseph Bove, vice president of business development at Stellar, an architecture, engiwww.profoodworld.com

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SANITARY PLANT DESIGN

neering and construction firm based in Jacksonville, Florida. “A lot of facilities are trying to isolate areas so they can run their processing equipment longer and have less clean-up time or less time between.” To further prevent cross-contamination, a plant should create a linear flow for the production process whenever possible, according to Elyar. A linear production flow allows the plant to map out and control how employees, products and materials will navigate through the areas of the facility. As part of that linear flow, there should be controlled access points for employees and visitors in order to control hazards and prevent cross-contamination. In addition, high-risk areas should have controlled access through sanitation stations, where employees must undergo a hand and boot wash and don gowns. Elyar recommends that in certain processing environments, employees wear color-coded gowns so that they can easily recognize when someone is out of place in the facility and possibly creating a cross-contamination risk by allowing pathogens or allergens to travel from one part of the plant to another.

Some food and beverage companies use vitrified tiles for their flooring because they are nearly impermeable to moisture, can stand up to abrasive materials and harsh chemicals, hinder bacteria growth and can handle extreme impact loads. Photo courtesy of MSKTD & Associates.

“Promoting a linear flow of that process line also helps eliminate product crossover, an important part of hygienic design. We want to receive ingredients at one end of the plant and then work to formulate a linear flow, so those raw ingredients are processed by moving down the line to the finished goods end of the plant,” Elyar says. “This also helps with controlling people flow, so employees are less likely to cross over different hygienic zones of risk.” For employees, maintenance staff, visitors and others that must veer away from the linear process flow, Elyar endorses the integration of a sanitation corridor between areas and rooms. “When an employee leaves that high-risk area, they can go back into a sanitation 38

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corridor, which allows for the movement of people and equipment around processing areas,” he says. “In order to re-access a processing area, employees will have to re-enter through a sanitation station as a means of isolating the various hygienic zones.”

Up in the air The ability to control temperature, humidity, airflow and air quality is another critical component of sanitary plant design because it can inhibit microbial growth. A plant’s HVAC unit and refrigeration systems must maintain the optimum temperature and control the air dew point for every part of the facility as the product makes its way through the manufacturing process. By doing so, the HVAC and refrigeration systems ensure the safety of the product and prevent the development of humidity, condensation and fog, which are the moist conditions that are conducive for bacteria to grow and multiply. “A food processing facility is really a manufacturing facility on steroids,” Koury says. “It has often times everything from subzero temperature warehousing to where you have every room temperature in between that and 80°, where the ovens are, and then back down to a chilled environment for outgoing product. Any time you have that wide range of temperatures, you have to be aware of where your temperature zones are and monitor them.” The HVAC units must also filter the air and maintain positive air pressure at all times in the plant. That entails pumping the filtered air into the most sensitive area with the strictest hygiene requirements. Because the air in that particular area is sterilized, the HVAC system should create high air pressurization in that area and push that clean air to other areas of the plant. In addition, the positive air pressure should keep outside air — and all the microbes, dust and allergens that come with it — from entering the facility. “Pressurization in the plant always goes from the areas of highest bacteriological control, such as a ready-to-eat area, then the air needs to move to lesser hygiene zone areas,” says Ed Wright, project executive at The Austin Company, a design-build firm based in Cleveland, Ohio. “With pressurization, you can push quality-controlled, tempered air to the places (hygiene zones) you want it, and you can control the quality of the air by pushing that pressure,” Bove says. “With airflow, you don’t want lower-hygiene zone air getting into higherhygiene zone air. For example, if you have raw areas with raw product, you don’t want that air getting into the ready-to-eat air. And so, with mechanical equipment, duct work and pressurization of air, you can separate and even push air from one area of higher hygiene to another area of lower hygiene.”

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SANITARY PLANT DESIGN

Easy to clean A well-developed sanitary design plan also ensures that the facility and equipment can be easily maintained and sanitized to a microbiological level. That means construction materials and equipment must be extremely durable; resistant to wear, cracking and bacteria; and highly cleanable. “A lot of [our sanitary design] was focused on ease of cleaning. Most people don’t realize that cleaning is the biggest driver for downtime in a food facility. You have to take your production down so that you can clean it,” says Michael Druga, president and CEO of SinnovaTek, which sells microwave-based sterilization equipment for pasteurization and aseptic processing. Druga previously owned Wright Foods, a processor of aseptic fruit and vegetable purees, soups and sauces from 2012-2016. “Proper sanitary design makes it much easier to clean and provides a more efficient process. You can get in and out of production runs much faster,” he says. “With better design, you have better production.” According to many food and beverage manufacturers, flooring is one of the most important parts of a food and beverage facility. Plant floor high-traffic zones must contend with water accumulation, food and debris buildup, harsh cleaning chemicals and hot water during washdowns, and thermal cycling. Those factors make floors susceptible to erosion and cracks that could harbor debris and bacterial growth. To protect the floors from wear and tear, many food and beverage plants choose to use concrete flooring with a urethane concrete coating. Urethane creates a

cleanable surface that inhibits the growth of bacteria, can withstand organic acids in foods, resists chemical damage, is water resistant, can handle the thermal shock of fluctuating temperatures, and adds skid resistance to the floors to enhance employee safety. In addition, urethane dries and cures in hours to minimize downtime. “Going back 15 years ago, most companies wanted an epoxy floor. But in the food and beverage industry, you have acids from food and chemicals from the sterilization process and the abrasion from water, and epoxy breaks down over time,” says Casey Ball, market segment director for flooring for the protective and marine coatings division of Sherwin-Williams. “Urethane concrete has a high degree of chemical resistance, and it’s tolerant to moisture problems from concrete.” However, George Bachnivsky, vice president of MSKTD & Associates, an architecture and engineering firm with offices in Fort Wayne and Indianapolis, Indiana, recommends vitrified tiles for flooring in food and beverage plants. He says they are 0.0009 percent impermeable to moisture, can stand up to abrasive materials and harsh chemicals, hinder bacteria growth and can handle high impact loads. In extreme or harsh environments, vitrified tiles last about three to four times longer than urethane coating, he says. “Vitrified tiles are highly chemical resistant. They don’t discolor. They can take a lot more abuse. From a life cycle standpoint, they will outlast urethane floors,” Bachnivsky says. “But you’re going to pay more than twice the amount for them.” Flooring also plays a vital role in preventing water accumulation in the plant. Water is crucial in food

10 commandments for CIP design

LEAN-IN-PLACE (CIP) systems play an integral role in sanitary plant design. They not only help food and beverage manufacturers clean parts of equipment that are difficult to reach, but CIP minimizes cleaning time and the labor needed for it, ensures consistency and repeatability of the cleaning process, improves efficient use of water and cleaning chemicals, and ultimately increases the productivity of the plant. Here are some tips from The OpX Leadership Network’s CIP for CPGs Clean-in-Place Guidelines for Consumer Packaged Goods Manufacturers that will help food and beverage manufacturers design effective CIP systems. 1. Always remember that water runs downhill … 2. … and that it is easier to pump water into a tank than to pump it out. 3. Pitch tank “CIP Return” Manifold/Connections continuously to pump inlet. 4. Keep tank head nozzles few in number, short in length and large in diameter. 5. Avoid 3-port divert valves like the common plague. 6. Design to close all valves against flow. 7. Locate CIP systems in (near) and (when possible) beneath the center of CIP loads. 8. Eliminate all “Dead Ends” (branches of more than 1-1/2 pipe diameters), for they will trouble you forever. 9. Pitch all lines to easily opened drain points. 10. Design and install supports to eliminate “friendly” piping that waves when starting pumps and opening and closing valves, for friendly systems are short lived. To download the CIP for CPGs Clean-in-Place Guidelines for Consumer Packaged Goods Manufacturers and the CIP for CPGs Clean-in-Place Checklist, please visit www.opxleadershipnetwork.org.

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SANITARY PLANT DESIGN

and beverage processing and sanitation, but when it starts to puddle, it can become a breeding ground for microorganisms. Proper sanitary design allows water to drain easily. Many food and beverage plants continue to use sloped floors that are angled to the lowest point in the room, where drains are placed, to prevent ponding. And to keep water from building up at the junction where the floors and walls meet, many engineering firms recommend using cove bases instead of 90-degree angles to eliminate water accumulation and prevent water from seeping through the walls. “I would stress the implementation of a cove base so that it has the floor-to-wall transition promoting proper water movement during washdowns and eliminating that area between the floor and the wall that can harbor bacteria and water getting behind the wall,” says Rebecca Dolton, regional market segment director for the food, beverage and pharmaceutical markets at the protective and marine coatings division of Sherwin-Williams. Insulated metal panels (IMP) are another material of choice for walls and ceilings because they are hygienic, durable and efficient. IMPs, which consist of two steel skins injected with urethane foam insulation

between them, are solid and flat with no indentations and have airtight and watertight seals. Therefore, they don’t harbor bacteria. In addition, the sanitary surface can be washed down and can withstand aggressive cleaning chemicals.

Equipment essentials Many of the criteria that guide the sanitary requirements for construction and building materials also apply to a plant’s equipment. Food and beverage manufacturers should purchase equipment that is nonporous, resistant to harsh cleaning chemicals and bacteria, and easy to clean. As a result, manufacturers often buy equipment made of high-grade stainless steel and that offer clean-in-place (CIP) functionality. “CIP has always been a way to try and reduce the manual intervention because every time you take something apart and put it back together again, there’s potential risk that something was missed, parts are misplaced or misaligned,” says Jeff Matis, senior associate and project manager for Kansas City, Missouri-based CRB, an architecture and engineering firm. “The turnaround time to clean in place is obviously a way to try and reduce the time it takes to clean a system and put it back in service.”

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CIP systems also offer repeatability once you’ve established the procedure of cleaning, Matis adds: “With COP (clean out of place), besides being labor intensive, it is also not a repeatable function. It becomes a procedural operation and not one that is easily controlled.” Placement of equipment is also important in sanitary plant design. All equipment should be situated away from walls and elevated off the floor to give workers enough space to access and clean the equipment and rooms. “When equipment is set in a room, you want to have enough room to operate safely so people can move around it,” Bove says. “But also, you want to have enough room so that it can be maintained and it can be washed. If you have a piece of equipment too close to a wall or it’s awkwardly positioned in a room, somebody may not go over and clean it.” According to Druga, the biggest challenge he faced when constructing the Wright Foods plant was keeping equipment off the walls and floor. “We put everything up on stands and got them a couple of inches off the floor,” he says. “That was really kind of a pain, especially on big pieces of equipment. It’s very easy to set them flat on the ground, but then you have to think

long term and ask yourself, ‘How am I going to clean this after installation?’” “It’s expensive from an installation standpoint, too,” Druga adds. “You’re constantly having to drill into your floor and install stand-up bolts in there, and you have

Cove bases eliminate water accumulation and prevent water from seeping through walls. Photo courtesy of Sherwin-Williams.

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SANITARY PLANT DESIGN

to come back and seal them in. It definitely has a lot of cost, a lot of labor and complexity. You’re trying to put pieces of equipment in there with a crane and line up these little bolts that have to be accurate within a fraction of an inch. It just makes it a more difficult install.”

Outside the box While most food and beverage companies are diligent about sanitation and food safety in their plants, sometimes they overlook the exterior of their facilities. For example, the roof can be prone to leaks and harbor bacteria if employees don’t monitor it regularly. To prevent those issues, many food and beverage companies are using a hygienic roofing system called a thermoplastic polyolefin (TPO) roof instead of a ballasted roof, according to Bachnivsky. With a ballasted roof, the membrane is made up of a gravel ballast that has proven to be problematic for food and beverage plants. The freeze-thaw cycles of northern climates produce cracks in the ballast, creating sharp edges that make it difficult and dangerous for employees to walk on the roof. In addition, ballasted roofs harbor bacteria, attracting insects. And the exhaust air from some food plants contain oil, which settles on the roof and degrades the membrane.

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A TPO roof doesn’t require a ballast. So it doesn’t have the costs associated with creating the structure to hold the weight of the gravel of a ballasted roof, freeing that structure to accommodate equipment or utilities. In addition, a TPO roof uses heat-welded seams that prevent bacteria from insects and other pests from entering the facility, and is resistant to oil from the HVAC system. The exterior areas of food and beverage plants should also incorporate pest control programs as part of their sanitary design plans, according to Patricia Hottel, technical director for South Elgin, Illinois-based McCloud Services, a pest management company. For example, she recommends that rodent bait stations be strategically placed around the perimeter of the facility. Trained personnel should monitor rodent activity and move the bait stations as needed. In addition, Hottel recommends that doors and dock doors are sealed completely to keep pests from entering the facility. Other tips for pest control: Landscaping for the facility should be limited to grass, rocks or pavement. Flowering plants, vegetation, mulch and bushes attract pests and encourage them to stay there. In addition, parking lots should be paved so water drains

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properly because ponding water tends to attract birds and mosquitos. And food and beverage facilities should use yellow LED or sodium vapor lights, which don’t draw insects like mercury vapor lights that emit a blue-violet light. When pest control programs and other sanitation strategies are executed properly, they work together to attain higher sanitary design goals for the plant. They not only optimize hygiene and operations, but ultimately position the company to succeed at food safety. “If we create a facility that promotes the most effective sanitary design, we are giving our clients the best foundation possible for them to implement a successful food safety program,” Elyar says. “When these critical elements are missed in the design phase, owners are required to implement costly manual procedures to meet their food safety requirements.” Sanitary design is unforgiving, and it’s not tolerant of compromises, Koury says: “I would say it’s a primary element to food facility design. It’s up there, if not the top consideration.” PFW A M King www.amkinggroup.com

The Austin Company www.theaustin.com CRB www.crbusa.com HANSEN-RICE, INC. www.hansen-rice.com McCloud Services https://mccloudservices.com MSKTD & Associates www.msktd.com Sherwin-Williams https://protective.sherwin-williams.com SinnovaTek www.sinnovatek.com Stellar www.stellar.net

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YD DU UT TS SE ES SA AC C Y D U T S E S A C Y DRY PROCESSING SOLUTIONS

Side-by-side beam-and-hoiststyle bulk bag dischargers allow for one frame to discharge peanuts while the other is reloaded. Photo courtesy of Flexicon Corporation.

JOINING FORCES Once Again Nut Butter doubles output and improves operator safety with new bulk bag dischargers and flexible screw conveyors.

NCE AGAIN NUT BUTTER has come far from its humble origins without compromising its founding values. When Jeremy Thaler and Constance Potter created the company in 1976, they bought a small, used coffee roaster to roast nuts and used discarded bulk pails from a bakery to pack their organic and natural nut butters — all in their 800-sqft basement. The employee-owned company’s commitment to sustainably made products and a business model that promotes transparency and integrity has earned it a steady, loyal following over the last 40 years. Today Once Again produces 12 million pounds of natural and organic products every year, including honey, sesame tahini and various nut butters. It distributes those products nationwide to retail, private label, foodservice, industrial and export customers. To meet the growing demand for its products and cater to customers concerned about peanut allergens possibly cross-contaminating other Once Again products, the Nunda, New York-based company built a new facility solely dedicated to peanut butter pro-

duction. The 37,000-sq-ft plant features two bulk bag dischargers and five flexible screw conveyors from Flexicon Corporation that gives Once Again a higher degree of automation and control to double production capacity while improving operator safety. Once Again installed Flexicon bulk bag dischargers and flexible screw conveyors in 2016 during the construction of its new peanut butter plant. The company decided to outfit the new plant with the Flexicon bulk-handling equipment because it was pleased with how its Flexicon equipment performed over the years in its older plant, which now only processes nut and seed products, including organic cashew butter, sunflower butter and hazelnut butter as well as organic and natural honey. In addition, employees were already comfortable using the Flexicon equipment, while the company is able to reduce the costs associated with spare parts management. “We had other Flexicon systems installed, so there’s a spare parts advantage in things like the flexible screws are all the same pitch and the same construcwww.profoodworld.com

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DRY PROCESSING SOLUTIONS

posed a larger risk to worker safety and ergonomics. The new bulk bag dischargers reduce physical strain on the employees, protect workers from being hit by a large burst of peanuts, and contain the fugitive peanut air and dust from contaminating the facility. “The Flexicon bulk bag dischargers have some nice features designed into them that gives you the ability to safely untie and open those bags,” Millen says. “The access door with the iris valve lets you reach up and get that bag open without getting the entire contents of the bag rushing out of this 10-in. opening. If for some reason the straps of the bag break, the peanuts are not going to drop on your arms and crush them.”

The iris valve controls the closing and opening of the bulk bag spout, letting the peanuts flow out gradually and preventing fugitive peanut air and dust into the plant. Photo courtesy of Flexicon Corporation.

Twice the throughput

tion. The gear boxes, the tubes and a lot of the other components in the system are cross-functional,” says Peter Millen, process engineer at Once Again. “So it minimizes our spare parts inventory.”

Safe and sound The new Flexicon equipment also helps to enhance worker safety at Once Again’s peanut butter plant, according to Millen. Two Flexicon BULK-OUT BFC bulk bag dischargers feed the new line. Each bulk bag discharger is equipped with a cantilevered I-beam, hoist and trolley that lift and position the bag in the discharger frame without the need for a forklift. When the raw and shelled peanuts arrive at the facility, they come in super sacks weighing 2,200 lb each. An operator attaches the bag straps to the lifting frame and actuates the electric hoist and trolley using a pendant to position the bag in the discharger frame. The bag’s outlet spout is pulled through an iris valve, which closes around the spout, preventing material flow. The operator then unties the drawstring, closes the access door, and releases the valve slowly to let peanuts gradually flow into the 5.5-cu-ft hopper. The dischargers are fitted with pneumatically actuated FLOW-FLEXER bulk bag activators, which increasingly raise and lower opposite bottom edges of the bag into a V shape as it empties and lightens, promoting complete evacuation. In the older facility, employees manually hoisted and emptied the super sacks of peanuts into the hopper of the roaster — a labor-intensive process that 48

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When Once Again built its peanut butter facility, it not only wanted to improve worker safety, but also increase its efficiency and double production capacity. With the Flexicon bulk bag dischargers and flexible screw conveyors, Once Again can manufacture up to 7,000 lb of peanut butter per hour, according to Millen. The two bulk bag dischargers ensure Once Again can continuously feed peanuts to its two new roasters. Positioned side by side, the bulk bag dischargers allow one frame to discharge material while the other is reloaded. It also provides redundancy in the event one of the systems is offline. The 20-ft long flexible screw conveyors transport the peanuts from each of the discharger’s hoppers at a 45-degree incline into a gravity separator. The gravity separator removes any foreign material that is lighter or less dense than the peanuts, such as twigs or peanut shell pieces.

One of the five flexible screw conveyors Once Again Nut Butter uses transports roasted peanuts from a transfer bin to a pneumatic conveyor line that takes the peanuts to the grinding phase of the peanut butter production process. Photo courtesy of Flexicon Corporation.

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From the gravity separator, a third flexible screw conveyor, which is about 15 ft long and angled at 45 degrees, takes the peanuts to the de-stoner to remove any material heavier and denser than the peanuts, such as pebbles. A 50-ft long pneumatic conveying line then loads the peanuts into an intermediate storage silo until they are ready to be roasted. Another 50-ft pneumatic conveying line transfers the peanuts from the silo to the roaster. Once the peanuts are roasted, a 70-ft pneumatic conveyor transfers them to a blancher, which removes the peanut skins. Another 70-ft long pneumatic conveyor delivers the blanched peanuts to two holding silos. From each silo, a 15-ft flexible screw conveyor feeds the peanuts to a roasted peanut transfer bin. Then another flexible screw conveyor transports the peanuts from the bin to a 90-ft long pneumatic conveyor line for grinding before going into packaging. Like the bulk bag dischargers, the Flexicon flexible screw conveyors bring convenience, control and consistency to the manufacturing process, according to Millen. Each of the flexible screw conveyors uses a flat wire spiral housed in an enclosed tube measuring 4.5 in. O.D. that prevents peanut air and dust from escaping into the facility. Plus Millen appreciates that the flexible screw conveyors take up a small footprint in the plant, integrates seamlessly with the plant’s equipment, including the gravity separator and de-stoner, and can be configured to various angles to accommodate the placement of the equipment in the processing line. “Without the Flexicon flexible screw conveyors, I don’t know that we would have been able to put the equipment in their current configuration in the plant and have it function effectively,” Millen says. In addition, variable frequency drives (VFD) control the drive motor rotating the screw. This enables operators to control the speed and torque of the conveyors so that the conveyors can adapt to the pace of the upstream and downstream equipment. VFDs also reduce the amount of power required at startup, eliminate voltage fluctuations, and reduce wear and tear on the motor, extending its life. With the flexible screw conveyors and bulk bag dischargers in place, Once Again has been able to meet its target production rates and set the foundation for future expansion, according to Millen. “We designed this facility to handle higher volume. We needed to produce more product, and we had to do it more efficiently,” Millen says. “The www.profoodworld.com

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ProFood World

Once Again Nut Butter now makes its organic and natural peanut butters at a new dedicated peanut butter facility. Photo courtesy of Flexicon Corporation.

Flexicon units give us the efficiency, the level of automation, integration and control over the entire system.” PFW Flexicon Corporation www.flexicon.com

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stops to optimizing labor use to reducing the likelihood of quality variation.

Joyce Fassl

Learn how leaders at the FSO Institute and Barry-Wehmiller have improved

Editor-in-Chief

performance of processing and packaging lines by using industry best practices

ProFood World

and tools from PMMI’s OpX Leadership Network-including an OEE Calculator. Speakers will share a Case Study on how they used the calculator—which is free to all CPG companies and suppliers as a means for unifying internal stakeholders around identification and prioritization of improvement efforts as well as:

SPEAKERS barrywehmiller

Director of Operational Excellence

• Set target performances for processing and packaging lines • Estimate labor needs and costs • Uncover savings through baseline performance

Bruce Williams

betterworld

Barry-Wehmiller

Madinah Allen Head Coach, FSO Institute, Former Senior Director of Corporate Engineering and Technology, Snyder’s-Lance, Inc.

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YD DU UT TS SFLOOR ES SA AC C Y D U T S E S A C Y E PLANT

NEW PRODUCTS In-tank mixer provides maximum flow The Admix Rotosolver high shear intank mixer is used for the wetting out of powders. The clean-in-place mixer delivers high-speed batch mixing and dispersion. Suitable for volumes up to 6,000 gal, it is 3-A compliant. Admix, Inc. admix.com

Monitoring device a major shift in pest control technology

Ribbon mixers are designed for small batch applications

A standalone Wi-Fi trap system, the VM Products EZ Square Rat electronic rodent monitoring device installs in 60 seconds or less anywhere there is a connection or hot spot. The device provides real-time notifications of a rodentâ&#x20AC;&#x2122;s presence, as well as the time and place of the rodentâ&#x20AC;&#x2122;s activity. VM Products vmproducts.com

Gardner L Series compact ribbon mixers are used to blend powders and granular materials. Featuring a full-length top cover opening for accessibility, they have interrupted spiral ribbon agitators that can be easily removed for cleaning. The mixers have a working capacity range of 1.8 cu ft to 14 cu ft (50 L to 400 L). Kemutec Group Inc. kemutecusa.com

High-capacity filler maximizes uptime and minimizes downtime Capable of filling up to 1,500 cans or glass containers per minute, the JBT Unifiller machine includes clearguarding that enables revision of the unit as it functions, LED lighting and built-in clean-in-place technology. The machine can be synchronized with the JBT 12-head seamer to provide a high-speed canning solution. JBT Corporation jbtc.com

Mixer meets the tight tolerances required in high shear applications Designed for the single-pass or batch-style processing of liquids and semi-solids, the Ampco SHEAR-max mixer incorporates a curved wedge-style rotor that allows solids into the shear zone rotor and a one-piece stator for easy inspection and cleaning. The unit can be used for inline high shear mixing, dispersing, dissolving, emulsifying, de-agglomerating, homogenizing or blending. Three models, with a maximum flow rate of 400 gpm, are available. Ampco Pumps Company ampcopumps.com www.profoodworld.com

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5/30/18 10:13 AM

PLANT FLOOR PRODUCTS

Pest control system meets FSMA requirements Created for food processing, packaging and distribution facilities, the Copesan Signature Care risk-based program focuses on preventing pest issues. Supported by its RapidTrax eLogbook paperless electronic documentation system, the program meets all regulatory requirements and can be customized to meet specific plant needs. Copesan technicians provide 3-D inspections to uncover pest-conducive conditions and determine facility trending for predictive analysis. When pest activity exceeds acceptable limits, e-alerts are sent, and a prepared corrective action plan is triggered automatically. Copesan copesan.com

Compact liquid ring vacuum pumps have a modular design Dolphin LM/LT liquid ring vacuum pumps feature integrated flow channels and FKM or FFKM mechanical shaft seals. Engineered for once-through circulation systems in open or closed liquid cycles, the pumps offer the vapor and particle tolerance to make them suitable for the removal or extraction of wet gases or vapors. Available with pumping speeds from 58 to 510 acfm, they come in different ATEX-compliant versions and temperature classes for operation in potentially explosive environments. The Dolphin LM models are single-stage vacuum pumps for a rough vacuum range from atmospheric pressure to 100 Torr ultimate pressure, while the Dolphin LT units are available in two-stage versions and cover a vacuum range from atmospheric pressure to 25 Torr. Busch LLC buschusa.com

Nobody likes cleaning, so we made it easy.

Multi-aperture metal detector reduces total cost of ownership Built for food packing and processing conveyor lines, the Fortress Technology multi-aperture metal detector can detect metal fragments as small as 0.8-mm ferrous, 0.8mm nonferrous and 1.2-mm stainless steel. Capable of being installed in a variety of multi-lane configurations, it only inspects and rejects contaminated products from each individual conveyor. A single control panel manages all the lanes, with each lane programmed to run independently from the other(s). Fortress Technology Ltd. fortresstechnology.com

Designed for easy and efficient cleaning and sanitizing. 800.640.6850 • www.DynamicConveyor.com 1806_PlantFloorProducts.indd 56

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June 2018

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ed s. or le on 58 ns ve m re re m

Variable intensity blender operates at high rates

Speed reducer features a fret-free motor connection The standard Winsmith RD speed reducer is dimensionally interchangeable with many companies’ quill-input, right-angle speed reducers. The Winsmith RD Max model has a stainless-steel nameplate and output shaft, as well as IP66 certification and X-ray- and magnetically detectable food-safety blue plugs. Both versions are suitable for applications involving general industrial processing and material handling equipment, such as food processing, bottling and packaging. Winsmith winsmith.com

The Munson VIM-124-SS variable intensity blender has six injection ports that allow liquids to be combined with bulk food materials to produce pastes and slurries continuously. Externally mounted bearings with air-purged seals support the large-diameter solid main shaft, which rotates within the cylindrical vessel. The agitator is driven by a 20 hp explosion-proof inverter-duty motor with an enclosed gear reducer and variable frequency drive that can rotate the agitator at speeds from 120 rpm to 600 rpm. Constructed of stainless steel, the sanitary unit yields up to 200 cu ft of throughput per hour. Munson Machinery Company, Inc. munsonmachinery.com

PROTECT AGAINST DOWNTIME, WASTE AND PRODUCT RECALLS Steam boiler is compact and lightweight Able to start up quickly and rapidly respond to fluctuating steam demand, the new Clayton Steam Master boiler comes in three sizes, with 40, 30 and 15 boiler hp. It can be equipped with optional packages, including a fuel-savings package, a steam-quality package, a water-treatment package to pretreat incoming water and handle returning condensate, and an automatic-start package. The boiler also can be equipped with full Ethernet communication capabilities, such as the ability to monitor and operate the boiler via a mobile phone. Clayton Industries claytonindustries.com www.profoodworld.com

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ProFood World

The Metal Detectable and X-Ray Inspectable Detectomer® line of Buna seals and Silicone gaskets and Ensinger’s Hydex® seals are now available for many of our Magnetic Separators. BENEFITS INCLUDE: • Protection against elastomeric contamination in the processing line. • Can be spotted by metal detectors, X-Ray systems, Optical scanners, as well as captured by Magnetic Separators. • Meets the FDA Code of federal regulations for food safety. • Complies with the Food Safety Modernization Act (FSMA) recommendations and the principles of Hazard Analysis and Critical Control Points (HACCP).

Industrial Magnetics, Inc. 888.582.0821 • www.magnetics.com 5/30/18 10:14 AM

PLANT FLOOR PRODUCTS

Absorption mounts act as dampers

Dock shelter system keeps out contaminants and pests

RoHS compliant, Winco GN 256 conical-type silicone vibration/shock absorption mounts have stainlesssteel components and come with either a tapped hole or threaded stud. The incorporated silicone rubber material has an increased working temperature range. Capable of absorbing most of the accumulated kinetic energy on impact, they are typically used as end-stop bumpers and leveling feet. JW Winco jwwinco.com

The Rite-Hite Eclipse NH dock shelter seals against trailer sides, across the full width of the trailer top and at the corners. It does not interfere with trailer doors being opened and closed after a trailer has been parked at a dock, and facilitates drive-through applications. The shelter can be used with the RiteHite vertical storing dock leveler and PitMaster under-leveler sealing system to prevent contaminants and pests from entering a facility. Rite-Hite ritehite.com

Freeze-warning technology protects products in transit CTI BlindSpotz freeze-warning technology can be printed directly on a package to record whether an individual pallet, case or package has frozen in transit. The technology is embedded into an ink system that can be incorporated into existing printing processes. It is available in UV- and water-based flexo, water-based gravure, wet offset and UV-wet offset ink formulas. Chromatic Technologies Inc. ctiinks.com

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Mixer produces dust-free, homogeneously mixed dough Working as a pre-mixer for doughs produced in continuous batches, the Zeppelin DymoMix high-speed mixer features a nozzle in the rotating shaft that sprays tiny drops of liquid, building up a fine, liquid screen on a falling cloud of dry ingredients. The mixer can be incorporated on batch or continuous mixers or used as a stand-alone system. Typical applications include pizza crusts, pretzels, brews and sugar slurries, as well as noodle, bread, roll, sponge and pastry doughs. Zeppelin Systems zeppelin-systems.us

Pest control programs ensure proper preventive controls are in place Designed in accordance with all thirdparty auditing agencies, including GFSI, McCloud Services pest control programs are based on site surveys and risk assessments. The programs utilize a tactical approach, combined with quality initiatives and technology, to analyze data quickly and provide for the detailed, regulatory-compliant documentation of service programming, materials used, methods of application and pest activity trends. Typical services for the food industry include stored product pest protection; fumigation and fumigation alternatives; interior and exterior rodent inspection, management and control; bird and fly management; pest exclusion; food safety consulting; and employee training. McCloud Services mccloudservices.com

www.profoodworld.com

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PLANT FLOOR PRODUCTS

Packaging solution increases efficiency and reduces costs

BRIDGING THE SKILLS GAP

Designed for the snack industry, the BPA SPIDER 200i all-inone packaging solution erects and packs up to 10 cases per minute; it uses a multi-axis delta robot to pick on the fly snack bags and vertically case-pack them into a cassette, forming a vertical pack pattern. Options include auto changeover and a glue or tape top and bottom sealer. BluePrint Automation blueprintautomation.com

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Designed for integration with a metal detector to inspect bulk foods on processing and packaging distribution lines, the Key Technology Iso-Flo vibratory conveyor combines three conveyor bed sections: a stainless-steel infeed, a nonmetallic section that passes through the metal detector’s aperture and a stainless-steel section with a reject device. The infeed section can incorporate a screen capability to scalp or remove fines, small particles or water, if needed. Reject device options include a pneumatic gate within the shaker bed that opens and closes and a slide chute at the discharge of the shaker bed that switches direction if metal contamination is detected. Key Technology, Inc. key.net

Learn more at pmmi.org/elearning

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ProFood World

June 2018

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5/30/18 10:14 AM

Horizontal cartoner offers speed and versatility

Conveyor fits into tight or narrow spaces The Multi-Conveyor Slim-Fit hygienic product transfer conveyor has a toolless pin-pull approach that allows an operator to remove the belt quickly for routine maintenance. The unit includes a center drive design that keeps balance in the system and uniform depth or width on each end, a V-guided end pulley, a flip-up end tail that maintains tension and tracking, and a washdown stainless-steel frame. Available with optional casters, the conveyor can be adjusted in height from 30 in. to 48 in. Multi-Conveyor multi-conveyor.com

Capable of running a range of product sizes and types, the PMI Cartoning HS112 horizontal cartoner features a custom product infeed system and rotary sleeve/carton feeder that enables the unit to run at speeds up to 160 sleeves or cartons per minute. An integral pusher head ensures gentle product handling and loading. Available in stainless steel for washdown environments, the cartoner features a flap tucking and gluing area. Custom product transport systems can be added to feed a staging area to prepare cartons or sleeved trays for secondary packaging. PMI Cartoning, Inc. pmicartoning.com

PET container provides carrying advantages The Pretium 2-liter SureHandle PET container features an integrated handle. Validated by The Packaging School at the Rochester Institute of Technology for high-pressure processing food and beverage applications, the monolayer container and ergonomic handle are engineered for cold processing pasteurization and for products that need fill temperatures up to 120Â°F. It can accommodate an induction seal, foam liner or linerless plug-seal-style closure. Pretium Packaging pretiumpkg.com

X-ray inspection system conducts 10 product integrity checks

Gate allows unrestricted movement of personnel Compatible with any tabletop conveyor system, the Nercon ProCore conveyor retractable gate provides a standard 30-in. pass-through opening or can be paired back to back with another gate to extend the opening to 60 in. Operated by a hand crank, the gate horizontally retracts into itself. The unit comes with adjustable guide rails. Nercon nerconconveyors.com

The METTLER TOLEDO Safeline X39 X-ray inspection system detects and rejects nonconforming frozen formed beef, pork, chicken, fish and vegetarian burger patties. In stage one of the inspection process, integrated laser technology performs a preliminary brand integrity check for flake defects, as well as length, width and height irregularities. In the second stage, the system inspects for foreign-body contaminants and additional product defects, such as holes, dents, edge deformities, mass and shape. Air nozzles reject substandard product from the conveyor in the first stage and into a secondary rework receptacle in the second stage. The system operates at a rate of 60 meters a minute. METTLER TOLEDO Safeline mt.com/safelineus www.profoodworld.com

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ProFood World

5/30/18 10:14 AM

CASE CASE STUDY CASE STUDY STUDY

JAVA JOLT Fast-paced growth pushes Bean Box to upgrade to an automatic rotary premade pouch filling machine to speed up its packaging process and save on labor. MAYA NORRIS MANAGING EDITOR

EAN BOX IS SCALING UP — and fast. The Seattle, Washington-based company’s artisanal coffee subscription service is a hit with customers across the United States, earning Bean Box more than 100 percent year-over-year growth since it was founded four years ago. But to keep up with that growing demand, Bean Box had to take its startup operations to the next level. The company recently installed an automatic rotary premade pouch filling machine to increase the speed and scale of its packaging process and reduce labor costs.

Bean Box installed the Viking Masek 8S-235 automatic rotary premade pouch filling machine to help it efficiently package 35 tons of coffee beans a year. Photo courtesy of Bean Box.

When Matthew Berk and Ryan Fritzky launched Bean Box in 2014, they created a coffee-of-the-monthclub concept that capitalizes on Seattle’s reputation as a coffee mecca. Members sign up for the subscription service online at Bean Box’s website (https://beanbox. co/), where they indicate their roast preference (light, medium, dark, espresso, decaffeinated or all roasts). Every month members receive four varieties of coffee beans in 2-oz bags from independent, award-winning, small-batch roasters in Seattle. Bean Box ships out the coffee beans within 48 hours of roasting to ensure freshness and quality of the product. Customers may also order full-size 12-oz bags of any coffee from their subscriptions as well coffee gift sets. The company has since added small coffee roasters from Portland, Oregon — another city known for its coffee culture — to its subscription service. Bean Box packages and ships about 35 tons of 62

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coffee beans a year. Half of that volume is processed in December during the holiday season. Every week Bean Box receives about 200 different types of coffee beans from the 30 Seattle and Portland artisanal coffee roasters it works with. The coffee beans arrive at the Bean Box facility within hours of being roasted. The company then only has 48 hours to package the beans and ship the products to customers. Outside of the holiday season, Bean Box now ships between 2,500 and 3,000 boxes of coffee a week. To accommodate its growing customer base and meet its stringent turnaround time for shipping, Bean Box ditched hand-filling its packages in favor of an automated packaging system. It installed a Viking Masek 8S-235 automatic rotary premade pouch filling machine in the fall of 2017 that accelerates the packaging of its coffee beans, particularly during the company’s busy holiday season when it packages and ships about 15 tons of coffee beans in three weeks. “Being able to package coffee at real throughput is everything to our business. First, we needed to support packaging at a greatly enhanced scale to meet our demand for our holiday season peak. Secondly, we’re really growing our baseline outside of the holidays,” says Berk, co-founder and CEO of Bean Box. “And when you have that commitment of shipping the freshest possible coffee hours after roasting the beans, time is at a premium.”

The daily grind When the beans arrive at the Bean Box facility in tubs of up to 100 lb, operators load them into a hopper. A pneumatic conveying system transports the beans into a secondary hopper mounted above the scale, which is integrated into the Viking Masek 8S-235. An operator then manually loads Bean Box’s preformed Kraft paper stand-up pouches into the bag magazine at the front of the filling and sealing machine, shingling them in a single-file line. A bag feeding roller conveys the bags to the machine’s first station. When the machine’s proximity sensor detects the bag, a vacuum bag loader picks up the pouch and transfers it to a set of grippers attached to the machine’s rotating head. These grippers will hold and secure the bag as it makes its way through the remaining stations.

www.profoodworld.com

5/29/18 4:32 PM

Because Bean Box pouches have resealable zippers, the Viking Masek pouch filling and sealing machine has a mechanical zipper opening station to separate the zipper and the sides of the bag to make sure the pouch is open for filling. Vacuum suction pads open the gusset of the pouch, while opening jaws with suction cups catch the top sides of the bag and stretch them outward. At the same time, a blast of filtered air is blown into the bag to ensure it is fully opened. Based on the specifications the operator entered into the human machine interface (HMI), the scale then doses a specific amount of coffee beans into a plunging funnel, which is lowered into the bag. The funnel ensures the coffee beans are dispensed into the bag and prevents them from spilling over into the machine. The grippers then close the bag tightly. A hot seal bar seals the upper part of the pouch. A cooling bar passes over the seal to strengthen and flatten it and reclose the zipper. The bag is then transported down the line for packing into Bean Box boxes.

Brewing up benefits The Viking Masek 8S-235 fills and seals Bean Box’s preformed stand-up pouches at speeds of up to 44 bags per minute for the 2-oz pouches and 30 bags per minute for the 12-oz pouches. That’s a huge improvement over the manual, hand-filling method the company used in its first three years of operation, which only yielded about four to six bags per minute. Before it installed the Viking Masek machine, Bean Box used four linear scale and volumetric filling systems to package its coffee beans. It was a labor-intensive, inefficient process that required the operators to manually load only about 20 pounds of beans at a time into the hopper, hold each pouch beneath the vibratory infeeder tray and funnel, and release the beans by pressing a foot pedal. When the operators were working diligently, they could fill about nine bags per minute. But they usually only filled about four to six bags per minute, taking into account breaks, hopper reloading, pulling stacks of bags for filling and other tasks, according to Berk. In addition to enhancing Bean Box’s packaging speed, the Viking Masek machine has also reduced labor costs for Bean Box. The new automated machine only requires two people to operate it. The previous packaging line consisted of four machines that each required an operator, who worked at his or her own pace. To keep up with customer growth in 2017, Berk estimates Bean Box would have needed eight to 12 of those linear scale and volumetric filling machines, which wasn’t feasible from a staffing standpoint. “On the [Viking Masek] equipment, the machine operates at 40-plus bags a minute, no matter what the operators do. It scales to handle batches from as small

Every month Bean Box’s subscription service sends members a variety of coffee beans from independent, awardwinning, small-batch roasters in Seattle, Washington, and Portland, Oregon. Photo courtesy of Bean Box.

as 20 pounds to as large as hundreds of pounds,” Berk says. “The automation sets the pace, and the operators keep up with that, as opposed to the operator setting whatever pace they want [with the previous packaging equipment]. It’s a major difference in terms of how people work, and the output is incredible.” With the labor savings and increased speed of the packaging process, Berk calculates that Bean Box now spends less than 1 cent per bag fill using the Viking Masek equipment, as compared to at least 10 cents per bag with the previous packaging system. “It’s a pretty dramatic decrease in labor costs,” he says. Berk is also impressed with the changeover time. When switching between the 2-oz bag and the 12-oz bag, the operator inputs the dimensions for the width of the bag into the HMI so the grippers adjust accordingly. He or she then manually adjusts the magazine guide rails to accommodate the width of the pouch, moves the suction cups to adapt to the length of the bag and changes the size of the plunging funnel. “We can go from a small bag to a large bag or the other direction in probably six or seven minutes,” Berk says. Since installing the Viking Masek 8S-235, Bean Box has not only advanced its operations, but the improvement in packaging speed and scale has allowed the company to concentrate on enhancing its products. “The biggest overall advantage for us is that it’s changed our business from struggling with a low-value operation, which is stuffing beans in bags, to allowing us to focus on higher-value operations,” Berk says. “The most value we provide is featuring a variety of different roasts from great roasters and combining them into novel products that are beautiful to experience. That’s where we want to operate.” “We thought we were going to upgrade our packaging process, and, in the end, our packaging process upgraded us,” he adds. “It’s changed our game.” PFW Viking Masek https://vikingmasek.com www.profoodworld.com

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CASE STUDY CASE STUDY CASE STUDY AD INDEX COMPANY

/ WEBSITE

PAGE

ABB (formerly Baldor Electric Company) www.Baldor.com

COMPANY

/ WEBSITE

PAGE

Material Transfer www.MaterialTransfer.com

Admix www.Admix.com/profoodworld

Mitsubishi Electric www.Mitsubishipackaging.com

Allied Electronics www.AlliedElec.com

PFI—Precision Food Innovations www.pfi-global.com

Axon Corporation www.AxonCorp.com

MSKTD & Associates www.msktd.com

Beckhoff Automation www.Beckhoff.us/C6015

OpX Leadership Network www.OpXLeadershipNetwork.org

50, 67

Charles Ross & Son Company www.mixers.com • mixers.com/web-app

PACK EXPO International 2018 www.PackExpoInternational.com

PMMI E-Learning www.pmmi.org/elearning

Clayton Industries info@ClaytonIndustries.com

CSI Designs www.CSIdesigns.com/cip20

ProFood LIVE! 2018 www.ProFoodLive.com

Deville Technologies www.DevilleTechnologies.com

Rubber Fab www.Rubberfab.com

Dynamic Conveyor www.DynamicConveyor.com

SEW Eurodrive, Inc www.SEWeurodrive.com

Endress + Hauser www.us.Endress.com/food-beverage

Shambaugh & Sons www.Shambaugh.com

Festo Corp. www.Festo.us/ea

Strahman Valves www.strahmanvalves.com

Frick Industrial Refrigeration www.FrickRefrigeration.com

Technopak Ltd. www.Technopak.co.nz

Good Foods Group. LLC www.GoodFoods.com

Tetra Pak, Inc. www.Tetrapak.com/us/end-to-end-solutions

Hansen-Rice Construction www.Hansen-Rice.com

Triple S Dynamics www.SSSdynamics.com

Heat and Control www.HeatandControl.com

Urschel Laboratories, Inc. www.Urschel.com

Hurst Boiler www.HurstBoiler.com

VAC-U-MAX www.vac-u-max.com/SigmatureSeries

Industrial Magnetics, Inc. www.Magnetics.com

Van der Graaf www.VanDerGraaf.com/SSV

Cover onsert

Veolia Water Technologies www.Veoliawatertech.com

Key Technology www.Key.net KP (Klöckner pentaplast) Food & Consumer Products www.KPfilms.com Likwifier www.Ensightsolutions.us

Cover-3

Lubriplate Lubricants www.Lubriplate.com

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Wilden www.WildenDistributors.com

Cover-4

Cover-2

Wire Belt Company of America www.WireBelt.com

Zumex Food Engineering www.ZumexMastery.com

www.profoodworld.com

6/25/18 10:06 AM

YD DU UT TS SE ES SA AC C Y D U T S E S A C Y MACHINE SAFETY

PROTECTING EMPLOYEES AND EQUIPMENT WITH RISK ASSESSMENT A proper risk reduction protocol identifies potential hazards; focuses on reducing risk, not scoring it; and determines what is acceptable risk. JOYCE FASSL EDITOR-IN-CHIEF

Fred Hayes, PMMI director of technical services

ISK ASSESSMENT is a process that allows you to protect something of value. Food and beverage processors and machinery builders alike want to protect machine operators and other plant employees and keep the production floor safe. At the same time, processors must adhere to food safety and quality standards as well as productivity goals. In this inter-

view with PMMI’s machine safety expert Fred Hayes, ProFood World examines how to develop a proper risk reduction protocol.

PFW: Why is risk assessment important? Hayes: Risk assessment is required by safety standards. ANSI 155.1 2016 Safety Requirements for Packaging and Processing Machinery requires a risk assessment to determine if you have built the machine to an acceptable level of risk. Risk assessment is also a requirement of the European Machinery Directive to ship equipment into Europe. The machinery directive

The Hazard Control Hierarchy Most Preferred

Risk Reduction Measure

Examples

Influence on Risk Factors

Classification

• Eliminate pinch points (increase clearance) • Intrinsically safe (energy containment) • Automated material handling (robots, conveyors, etc.) • Redesign the process to eliminate or reduce human interaction • Reduced energy • Substitute less hazardous chemicals

• Impact on overall risk (elimination) by affecting severity and probability of harm • May affect severity of harm, frequency of exposure to the hazard under consideration, or the possibility of avoiding or limiting harm depending on which method of substitution is applied

Design Out

• Barriers • Interlocks • Presence-sensing devices (light curtains, safety mats, area scanners, etc.) • Two hand control and two hand trip devices

• Greatest impact on the probability of harm (occurrence of hazardous events under certain circumstance) • Minimal impact on severity of harm

• Lights, beacons and strobes • Computer warnings • Signs and labels • Beepers, horns and sirens

• Potential impact on the probability of harm (avoidance) • No impact on severity of harm

Training and Procedures

• Safe work procedures • Safety equipment inspections • Training • Lockout/Tagout/Tryout

• Potential impact on the probability of harm (avoidance or exposure) • No impact on severity of harm

Personal Protective Equipment (PPE)

• Safety glasses and face shields • Ear plugs • Gloves • Protective footwear • Respirators

• Potential impact on the probability of harm (avoidance) • Some impact on severity of harm

Elimination or Substitution

Guards and Safeguarding Devices

Awareness Devices

Least Preferred

Engineering Controls

Administrative Controls

Source: ANSI/PMMI B155.1-2016. www.profoodworld.com

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MACHINE SAFETY

Risk assessment is a top-level standard. If we look at the steps in a risk assessment (see table on this page), it is an iterative process. It starts off with setting the limits of what the assessment is going to do. In other words, what kind of machine is it, but also is it the risk assessment of the whole machine or just part PFW: Please explain the risk assessment of a machine? You need to define the scope of the risk process. assessment. Hayes: Risk assessment tells users what to do. In The second step is an important one: Identify the other words, what is the hazard? What do I have to do task and hazard. If you don’t identify the hazards, you to implement risk reduction measures for that hazard? A can’t analyze the risks. How do you do that? Well, obvirisk assessment may say there’s a hazard here, and we’re ously, you look for mechanical hazards, such as run-in going to put a guard on it. There are other standards, nip points [e.g., two rollers running together or a consuch as ANSI B11-19 Performance Requirements for Risk veyor belt that goes around a pole] and energy sources. Reduction Measures: Safeguarding and Other Means of An example of stored energy is an elevator on a palReducing Risk that tell you how to build the guard. letizer. When that elevator’s up in the air, a certain amount of enerThe Risk Assessment Process gy is stored, but if that elevator 1. Prepare for/Set Limits of the Assessment (6.2) is released, it’s going to come down. That could be a hazard. 2006/42/EC Annex I lists the steps of risk assessment. The U.S. has regulations for risk assessment, such as HACCP (hazard analysis critical control points) or FSMA (Food Safety Modernization Act).

2. Identify Tasks and Hazards (6.3)

PFW: Please define taskbased risk assessment and provide examples. Hayes: This is where you look

3. Assess Initial Risk (6.4) Risk Scoring Systems

The Risk Assessment Process

4. Reduce Risk (6.5) Hazard Control Hierarchy

5. Assess Residual Risk (6.6) Risk Scoring Systems

6. Residual Risk Acceptable?

Go to the Next Task/Hazard

Yes

7. Validate Risk Reduction Measures (6.8) 8. Results/Documentation (6.9)

Source: ANSI/PMMI B155.1-2016.

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June 2018

Assessment Complete

at what workers do and the hazards they’re exposed to. When someone is going to clear a jam, you don’t want the machine to move or restart. Another example is when someone is cleaning a machine in a dairy. Sometimes they have to clean the machine with the doors open and the machine moving. Third-shift workers who are tasked with cleaning may be exposed to hazardous chemicals used for cleaning. This is where task-based risk assessment will help you find more hazards. Let’s use the example of cleaning the machine with a door guard open, and the machine has to be moving. There are ways to safely do that. The machine can be set to run slowly with the operator using a live-man switch to control it. Once you have identified a hazard, you need to evaluate the risk with a scoring system. A risk matrix is a method used by many companies. (See table on Page 68.) This matrix is easy to under-

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PACKAGING AND PROCESSING MACHINE GUIDELINES FOR CPGs AND OEMs

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MACHINE SAFETY

Example of a Risk Scoring System Severity of Harm Probability of Occurrence of Harm

Catastrophic

Serious

Moderate

Minor

Very Likely

High

Medium

Likely

High

Medium

Low

Unlikely

Medium

Low

Negligible

Remote

Low

Negligible

Source: ANSI B11.0.

stand and use. Look at where you think you are in the matrix, and then determine how to get to a better place and reduce the risk.

PFW: How should food processors prioritize time and effort spent on risk assessment? Hayes: Spend your money and efforts on reducing risk, not scoring it. It’s very easy for people to get hung up on risk scoring. We have found that you can have three teams score the risk associated with a hazard slightly differently, but they all pick the same risk reduction measures. Once you have identified a hazard and you want to implement risk reduction measures, the engineering hierarchy of controls section shown on Page 65 basically starts with engineering the hazard out. These are design changes where you eliminate the hazard or you substitute something else. Then you get into engineering controls, which are barriers, interlock devices, presence-sensing devices. Next are awareness devices, such as lights and beacons and warning signs. Finally, you have administrative controls, such as procedures and training. Procedures and training are important, but they’re even less effective than, for example, having a guard in a certain area. You put a guard on the machine and warning label with the guard. Plus, you should include this in training employees. At this point, you should be at an acceptable risk. When you’re reducing risk, usually you’re reducing the probability of the harm, not the severity. For example, on a palletizing machine, there are things inside the guards, such as moving chains and belts, etc. The barrier guard prevents contact with the hazards, but doesn’t reduce severity of an injury if you come in contact with the hazard. The guard reduces the probability of becoming entangled. Depending on how simple or complex the machine is, you may come up with more than 100 task hazard 68

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June 2018

pairs or line items on the risk assessment for a packaging machine. Some machines could be less. Some could be a lot more. The risk assessment process works if you follow it. The most important things are to identify the hazards; focus on reducing risk, not scoring it; and determining what is acceptable risk so you have an endpoint.

PFW: How can food and beverage processors and OEMs collaborate to reduce risk? Hayes: There are times when the machinery builder and purchaser of the machine have different definitions of what is acceptable risk or how you get there. For example, a food company may want a certain type of control system or certain types of interlocks. Instead of a guard and interlock switch, the customer wants a light curtain. An interlock switch works well with a guard, but this processor wants a light curtain for a particular reason. That’s OK, but it’s probably going to be an upcharge because that isn’t the standard for the OEM. It’s important that the machinery builder specify the architecture or performance level for the safety system and that it only applies to the “safety-related parts of the control system.” An example of why this is important: A machine tool that has a spindle, a table and coolant system. If you open an interlocked guard and the spindle starts, the operator can be injured. On the other hand, if the coolant system fails while an operator is inside the guard, they may get wet! Does the coolant system really need to be category 3? If a food or beverage company buys three pieces of packaging machinery, the integration may either be done by an integrator or by the plant. The machines may be from three different builders. Some additional guarding may be required at the machine interfaces, but no one knows what it should be because the line is not yet integrated. Hazards should be assessed as part of the integration process. PFW

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