What’s New in Food Technology Jan/Feb 2011 by Westwick-Farrow Media

Fill one bulk bag per week or 20 per hour at the lowest cost per bag Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements FILLER FOR PALLET JACK BAG REMOVAL Low profile version of patented TWIN-CENTREPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options.

BULK BAG FILLER USES PLANT SCALE Full length forklifting tubes allow positioning of this TWINCENTREPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls.

FILLERS WITH AUTOMATED FEEDING SYSTEMS Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters to interface with optional overhead storage vessels.

COMBINATION BULK BAG/DRUM FILLER Patented SWING-DOWN® filler features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums.

PATENTED SWING-DOWN® FILLER Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations.

CANTILEVERED REAR-POST FILLER Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system.

BASIC FILLER FOR TIGHTEST BUDGETS A lighter-duty version of the economical TWIN-CENTREPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options.

PATENTED TWIN-CENTREPOST™ FILLER Two heavy-gauge, on-centre posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust. Numerous performance options. First filler to receive USDA acceptance.

See the full range of fast-payback equipment at flexicon.com.au: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Tippers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

AUSTRALIA sales@flexicon.com.au 1 300 FLEXICON

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contents

food for thought

January/February 2011

ingredients and developments

processing 16 Fatal rockmelons kill 30

©iStockphoto.com/malerapaso

©iStockphoto.com/Lauri Patterson

©iStockphoto.com/Dragon Grkic ©iStockphoto.com/Oleksiy Mark

31 Food pairing and shared flavour compounds

33 37 46 50 testing and quality packaging assurance

39 The real and digital worlds of packaging 44 Packaging news

dairy

46 Yoghurt concept to functioning plant in eight months

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bulk handling, storage & logistics 54 Antibacterial soap more effective than non-antibacterial soap

Jan/Feb 2012

©iStockphoto.com/Diane Diederich

Crumbs from my table So, here we are in 2012. Hopefully we are all the human equivalent of brighteyed and bushy-tailed and ready to go. However, with the Australian and New Zealand food industries the question is really “Go where?” There is a lot of kerfuffle in the mainstream media about international companies buying up Australian food processors and moving manufacturing offshore to access cheaper labour and ingredients. While this is happening and will continue to happen, I don’t know that this is at the heart of the local food industry malaise. Over the last decade the power structure of the industry has altered dramatically. Where once the processors dictated play within the industry, now it is the retailers who call all the shots. If the pool of retailers was larger, the competition between them would create more scope for innovation and development among processors. But this isn’t the case. Instead we have just two (at best, three) retailers who now, essentially, control the local food industry. This situation is not all bad - the production conditions have improved in many food plants as a direct result of their having to comply with the certification requirements of the major retailers. This has to be a bonus for consumers as the quality and safety of the food and beverages they purchase is assured. But the downside for consumers and food manufacturers is the control the retailers have over what products are available for sale. If a retailer doesn’t accept a product it is doomed to specialist niche shops and will have limited exposure to potential consumers and hence limited production runs. There is no transparency in how the large retailers select items for sale but one is forced to assume that profitability for the retailer would be a major factor. This means processors have to trim their costs to the bone, which affects the funds they have available for product development and marketing. While I am in a complaining mode, I will add my concerns about honesty in labelling. As a consumer I expect that the front of a label will inform me what it is I am buying. If you are interested in my contretemps over differentiating roast beef from “moisture infused” beef which was actually only 81% beef, read So, what’s in a label? on www.foodprocessing.com.au. All I can say is that I have not purchased any meat from a supermarket since. Please keep in touch through 2012 and let me know of anything exciting happening in your section of the food and beverage industry.

Jan/Feb 2012

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Happy New Year Janette Woodhouse Chief Editor What’s New in Food Technology & Manufacturing www.foodprocessing.com.au

ÂŠ iStockphoto.com/ Kelly Cline

AIFST to offer a Continuing Professional Development program

Food innovation plant opens in NZ The FoodBowl, a government-backed food innovation pilot plant which aims to grow New Zealand manufactured food exports to $150 billion (270%) by 2025, has officially opened. Aimed at all food and beverage companies, from start-ups to SMEs and corporates, resources include commercial and test kitchens, laboratory facilities, pilot plant testing (from existing to leading-edge technology) and short-run processing capability to allow in-market testing of new product concepts. Located near Auckland International airport, The FoodBowl is part of a New Zealand-wide open-access network of innovation centres. The New Zealand Food Innovation Network, or NZFIN, comprises food science and technology resources designed to enable New Zealand food and beverage businesses of all sizes to grow, by supporting new product and process development with preproduction pilot facilities and expertise. The Auckland centre includes seven process halls: 1. Equipment for extrusion and milling/blending, filling equipment to handle bulk bags or retail packs for both extruded product and powdered blends. 2. UHT/aseptic filling line and other equipment for beverage development and production. 3. General purpose, for consumer goods including cans, retort pouches, stand-up pouches, bottles and jars; general purpose food processing and bar extruder and capacity to bake biscuits, health bars and novelty items. 4. High-pressure pasteurisation (including a 55 L HPP, which is being used to remarkably extend the shelf life of exports). 5. Freeze drying. 6. Microwave thawing. 7. Production kitchen. The FoodBowl, Palmerston North and Canterbury are operational and Waikato will follow in 2012. Each regional hub is focused on industries germane to the region (in Waikato there will be a primary concentration on dairy, while the Canterbury centre (at Lincoln University) supports South Island-based manufacturers and the Palmerston North hub draws on the expertise of some 600 scientists and technologists in NZFIN partner facilities, including Massey University and AgResearch). 10

Jan/Feb 2012

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In July 2011, AIFST announced its intention to introduce a Continuing Professional Development (CPD) Program for members. This was in response to the recognition that although professionals need to develop skills, knowledge and expertise throughout their careers, many find it difficult to continually document and update their achievements. This can make the job of articulating their abilities during career changes, whether planned or unplanned, difficult. AIFST is working towards implementing a CPD program that provides a systematic and planned approach to maintenance and development of knowledge and skills, throughout a professionalâ&#x20AC;&#x2122;s career. The program will focus on delivering relevant and targeted training and development opportunities for members. It will build on the scientific and technical program currently available and provide benefits to individuals, employers and the industry. A Calendar of Events - is currently available on the AIFST website (www.aifst.com.au) and this will be broadened to include non-technical events in the areas of leadership and management. We will be holding events to address current topics of interest at both national and international levels. Career planning and management - an online selfassessment tool tailored to graduates will be launched at the AIFST Australian Food Science Summer School 1-3 February 2012, at Trinity College, Melbourne. A Food Industry Career Map to assist members in their navigation of the industry is currently being developed. The way forward - we are currently recruiting for a National Technical Program Co-ordinator, a new role within AIFST designed to ensure the development, and the delivery, of the CPD program. For information on membership, contact the AIFST office Tel (02) 83993996 or www.aifst.com.au. Contact the CPD Team at cpd@aifst.com.au to find out how to get involved in the program.

Australian Institute of Food Science and Technology (AIFST)

Zero trans fat residue clean-up Exelerate ZTF is a cleaning program designed to address zero trans fat oil build-up in food processing environments. Frying or baking food with zero trans fat oils has the unexpected consequence of coating processing residue. Ecolab’s Exelerate ZTF helps food manufacturers clean zero trans fat residue from processing equipment and surfaces in half the time of other cleaning methods. The gelled product application clings to equipment and surfaces to dissolve zero trans fat soils, making it easier to clean. As food processors make the switch to using zero

Threaded 316 stainless steel orifices and snubbers Noshok offers a variety of orifices and snubbers to protect instrumentation from pulsation and pressure spikes by restricting the flow of rapidly increasing and decreasing pressures. Threaded 316 stainless steel orifices and press-fit brass orifices are available on all Noshok pressure gauges

trans fat oils, they have discovered that removal of polymerised soils from processing equipment and environmental surfaces is difficult and time consuming. Exelerate ZTF reduces the cleaning time by as much as 50%, helping processors reduce downtime and improve plant productivity and efficiency. Ecolab Pty Ltd Contact info and more items like this at wf.net.au/K654

and most Noshok transducers. They are standard with a 0.012″ ID or 0.032″ I., depending on the model. These orifices don’t take up space as they are inserted inside the NPT. They are an economical solution for managing pressure fluctuations in dynamic applications. Piston-type and sintered snubbers are also available. The piston-type snubbers resist clogging and are selfcleaning. They are supplied with five different-sized pistons to ensure the correct amount of snubbing for virtually every application. They are available in 316 stainless steel and brass in 1/4″ NPT, 1/2″ NPT or 7/16-20 SAE-4. Noshok sintered snubbers increase gauge readability by smoothing out pressure surges, pulsations and spikes, and eliminate instrument failure due to pressure shock. Snubbing action is achieved by utilising a corrosionresistant 316 stainless steel sintered disc, which is held in place by way of a 316 stainless steel set screw. The sintered snubbers allow easy cleaning or replacement of the sintered disc by simply removing the set screw, replacing the disc and then re-inserting the set screw, eliminating the need to replace the entire unit if a new disc is required. This type of built-in versatility increases the snubber’s longevity, durability and dependability. Five basic discs are available for each sintered snubber to accommodate specific application needs. Exotic materials or intermediate disc grades are also available on a per order basis. These snubbers provide long service life with no moving parts to wear out. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/K600

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PROCESSING

equipment and environmental surfaces with a stubborn

Ovivo supplies advanced water treatment plant for Viterra’s malt facility PROCESSING

two immersed membrane trains reducing TSS levels and pathogens. The MBR permeate is further treated through a dual-stage RO system to remove dissolved content and pH corrected before being stored for re-use. The process designed by Ovivo incorporates the use of a bioselector that conditions the wastewater prior to biotreatment and enhances biological phosphorous removal. The AWTP, which is capable of treating a hydraulic load of 300 kL per day, can recover 75% of the wastewater which equates to approximately a 50% reduction in Viterra’s reliance on local potable water supply. Ovivo was able to provide the client with capital cost savings over conventional activated sludge systems. The AWTP performed the same function but with a reduced footprint and associated civil installation costs. The technology used resulted in a compact and efficient means of improving water quality and is well suited for re-use applications. The AWTP, which was delivered as design, build and operation (DBO),

Viterra’s Tamworth malt facility has a grain capacity of 45 kt and supplies malt both domestically and internationally. The plant required an advanced water treatment plant (AWTP) to treat malting steep water to a quality suitable for re-use within the facility. Ovivo Australia designed and constructed a cutting-edge AWTP using membrane bioreactor (MBR) and reverse osmosis (RO) technology. The MBR and RO perform all the necessary steps to treat the influent to a condition suitable for re-use within the client’s facility and to maintain discharge agreement conformance for the reject stream generated. The malting steep waste is initially screened, balanced, pH corrected and biologically treated to reduce BOD/COD, nitrogen and phosphorous. Permeate is drawn through

Jan/Feb 2012

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enables water savings of 50 ML per year. Since commissioning, plant reliability has been stable with minimal requirement for process adjustments. The aeration system uses Ovivo’s Aerostrip Fine Bubble Diffusers, a high-performing membrane diffuser that has provided high SOTR against power input. The efficiency has been shown as 4 – 4.2 kg O2/h/kW input. Optimisation of the positive displacement blowers is achieved through Ovivo’s DO control strategy. The plant is controlled via a SCADA system that allows for remote monitoring and trending. This type of advanced water plant is the fifth of its kind that Ovivo has completed for the Australian food and beverage sector. The experience has shown that production of potablegrade water for non-potable re-use from industrial trade waste is a reality, with proven long-term operational stability and reliability. Ovivo Contact info and more items like this at wf.net.au/M215

Servicing the Food Industry for over 30 years Food grade hoses for all applications - FDA approved Standard grade and Premium grade food hose options available Stainless steel end connectors in BSM, RJT and Tri Clover All food hoses hygienically assembled All food hoses pressure tested, tagged and capped Wash down hoses and guns, pressure wash hoses and accessories Protect lanolin lubricant that is 100% natural and food grade approved 89 convenient locations Nationally, all IS09001:2008 accredited

PROCESSING

Fatal rockmelons kill 30 With a final death toll of 30 people, including one miscarriage,

Janette Woodhouse

the US’s most deadly outbreak ever of food poisoning has been declared over. In total, 146 people across 28 states became ill after eating Listeria monocytogenes contaminated whole rockmelon. While the number of deaths was not the largest ever recorded for a food poisoning outbreak, the greater than one in five death rate makes the outbreak of listeriosis the deadliest food poisoning incident in the US. The outbreak was also the first caused by whole, unprocessed produce.

istorically, Listeria monocytogenes contamination has been associated with ready-to-eat and processed food products, such as deli meat, unpasteurised cheese, raw milk, fresh-cut fruit and fresh-cut vegetables. The Gram-positive bacterium is typically thought of as an environmental contaminant of food plants. The bacterium is unlike most other foodborne bacteria in that it thrives in cold temperatures. Known reservoirs for Listeria monocytogenes include ruminant animals, decaying vegetation and cold, wet and difficult-to-clean environments. Symptoms of listeriosis can take up to two months to develop in someone who has eaten contaminated food, so there can be quite a long lag time between consumption of the pathogen and the identification of an outbreak. Often the contaminated food has been consumed and is no longer available before an outbreak is identified. In early September 2011, the Food and Drug Administration (FDA), in conjunction with the Centers for Disease Control and Prevention (CDC) and state health departments, began to investigate a multistate outbreak of listeriosis. By comparing the foods eaten by the outbreak cases, scientists were able to very quickly and convincingly show that rockmelons were associated with the outbreak. Early in the investigation, rockmelons from Jensen Farms in south eastern Colorado were implicated and subsequently identified as the sole source of the contaminated produce. Cases in other states were also quickly identified and linked to the growing outbreak through PulseNet, which is a national network of public health laboratories that conduct DNA fingerprinting on foodborne bacteria. 16

Jan/Feb 2012

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Multiple samples, including whole rockmelons and environmental (non-product) samples from within Jensen Farm, were collected for laboratory analysis to identify the presence of Listeria monocytogenes. Of the 39 environmental swabs collected from within the facility, 13 were confirmed positive for Listeria monocytogenes with pulsed-field gel electrophoresis (PFGE) pattern combinations that were indistinguishable from three of the four outbreak strains collected from affected patients. Of the 13 positive environmental swabs, 12 were collected at the processing line and one was collected from the packing area. Rockmelons collected from the firm’s cold storage during the inspection were also confirmed positive for Listeria monocytogenes with PFGE pattern combinations that were indistinguishable from two of the four outbreak strains.

Contributing factors A number of factors that were likely to have contributed to the introduction, growth or spread of Listeria monocytogenes at Jensen Farms were identified. In-field contamination Officials determined that potential routes for contamination of the rockmelons in the field included: • agricultural water • soil amendments • growing and harvesting practices • animal intrusion • adjacent land use • employee health and hygiene practices

©iStockphoto.com/JoeBiafore

Packing facility and cold storage contamination risks Potential routes of contamination during operations in the packing facility and cold storage included: • f acility and equipment sanitary design • c leaning and sanitising practices • w ashing and drying of rockmelons • c ooling of rockmelons • s torage of rockmelons • t ransportation Certain aspects of the packing facility, including the location of a refrigeration unit drain line, allowed water to pool on the packing facility floor in areas adjacent to packing facility equipment. Also, the packing facility floor was constructed in a manner that was not easily cleanable. Specifically, the trench drain was not accessible for adequate cleaning. This may have served as a harbourage site for Listeria monocytogenes and, therefore, is a factor that may have contributed to the introduction, growth or spread of the pathogen.

Equipment design FDA evaluated the design of the equipment used in the packing facility to identify factors that may have contributed to the growth or spread of Listeria monocytogenes. In July 2011, the firm purchased and installed equipment for its packing facility that had been previously used at a firm producing a different raw agricultural commodity. The design of the packing facility equipment, including equipment used to wash and dry the rockmelons, did not lend itself to be easily or routinely cleaned and sanitised. Several areas on both the washing and drying equipment appeared to be uncleanable, and dirt and product build-up was visible on some areas of the equipment, even after it had been disassembled, cleaned and sanitised. Corrosion was also visible on some parts of the equipment. Further, because the equipment is not easily cleanable and was previously used for handling raw potatoes with different washing and drying requirements, Listeria monocytogenes could have been introduced as a result of past use of the equipment. Environmental samples collected from the packing facility equipment tested positive for Listeria monocytogenes with PFGE pattern combinations that were indistinguishable from three of the four outbreak strains. After the firm discarded portions of the packing facility equipment and cleaned and sanitised the remaining packing equipment, environmental samples tested negative for Listeria monocytogenes. The design of the packing facility equipment, especially that it was not easily amenable to cleaning and sanitising and that it contained visible product build-up, is a factor that likely contributed to the introduction, growth or spread www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

All the environmental samples collected in the growing fields were negative for Listeria monocytogenes. However, FDA determined that the growing environment could not be eliminated as a potential contributor in the introduction of contamination. Specifically, low-level sporadic Listeria monocytogenes contamination from the agricultural environment and incoming rockmelons may have allowed for the establishment of a harbourage or niche for Listeria monocytogenes in the packing facility and cold storage.

Wet environments are known to be potential reservoirs for Listeria monocytogenes and the pooling of water in close proximity to packing equipment, including conveyors, may have extended and spread the pathogen to food contact surfaces. This pathogen is likely to establish niches and harbourages in refrigeration units and other areas where water pools or accumulates. The packing facility floor where water pooled was directly under the packing facility equipment from which FDA collected environmental samples that tested positive for Listeria monocytogenes with PFGE pattern combinations that were indistinguishable from outbreak strains. Therefore, this aspect of facility design is a factor that may have contributed to the introduction, growth or spread of Listeria monocytogenes. Another potential means for introduction of Listeria monocytogenes contamination into the packing facility was a truck used to haul culled rockmelons to a cattle operation. This truck travelled to and from a cattle operation and was parked adjacent to the packing facility where contamination may have been tracked via personnel or equipment, or through other means, into the packing facility. Based on the positive results from the environmental samples collected from the packing facility and from rockmelons collected from cold storage, it is likely that the contamination occurred in the packing facility. It is also likely that the contamination proliferated during cold storage.

PROCESSING

of Listeria monocytogenes. Rockmelon that is washed, dried and packed on unsanitary food contact surfaces could be contaminated with the bacteria or could collect nutrients for Listeria monocytogenes growth on the rockmelons’ rind. Postharvest practices In addition, free moisture or increased water activity of the rockmelons’ rind from postharvest washing procedures may have facilitated Listeria monocytogenes survival and growth. After harvest, the rockmelons were placed in cold storage. The rockmelons were not precooled to remove field heat before cold storage. Warm fruit with field heat potentially created conditions that would allow the formation of condensation, which is an environment ideal for Listeria monocytogenes growth. The combined factors of the availability of nutrients on the rockmelons’ rind increased rind water activity, and lack of pre-cooling before cold storage may have provided ideal conditions for Listeria monocytogenes to grow and out-compete background microflora during cold storage. Samples of rockmelons collected from refrigerated cold storage tested positive for Listeria monocytogenes. Auditing Five weeks before the FDA conducted its inspection at Jensen Farms, a third-party audit by Primus Labs gave the facility 96 out of 100 possible points. The facility was

Jan/Feb 2012

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found to have well-cleaned areas and no standing water. Everything was documented as easy to clean. This raises interesting problems for the US as it introduces its Food Safety Modernization Act, which incorporates third-party audits as standard procedure. Who will audit the auditors and will they be good enough?

Don’t let it happen to you The FDA’s findings regarding this particular outbreak highlight the importance for the industry to employ good agricultural and management practices in their packing facilities as well as in growing fields. Specific recommendations include: • A ssess produce facility and equipment design to ensure adequately cleanable surfaces and eliminate opportunities for introduction, growth and spread of Listeria monocytogenes and other pathogens. • A ssess and minimise opportunities for introduction of Listeria monocytogenes and other pathogens in packing facilities. • I mplement cleaning and sanitising procedures. • Verify the efficacy of cleaning and sanitising procedures. • P eriodically evaluate the processes and equipment used in packing facilities to ensure they do not contribute to fresh produce contamination. • E nsure third-party auditors are up to the task.

Innovative valve automation

PROCESSING

Metal contamination detection The Lock Inspection Systems Insight HD range of metal detectors features Optix, a powerful reporting and diagnostic software that clearly displays a detailed profile of the product for perfect set-ups, performance verification and timely reports. The detectors’ sensitivity can be finely tuned. Simply view the product signal and draw a detection envelope around it. Any signals detected outside this envelope indicate the presence of ferrous, non-ferrous metals or stainless steel contamination the products generating the signals can be automatically rejected. The metal detection and signal processing take place in the compact integrated digital search head. The Optix detector management software uses Lock’s DDS (direct digital signal) vector diagram to generate the detailed product profile needed to achieve perfect product set-ups. This ensures detection and rejection of metal fragments in both conductive and non-conductive product applications while achieving stable operation and high sensitivities to all metals. The comprehensive choice of reject options includes drop flap and retract band types. The failsafe option comprises reject confirmation, air failure alarm and bin full alarm. To help meet the hygiene requirements of the food and pharmaceutical industries, the Insight HD detector heads are sealed to IP69K/PW12. Each detector is delivered with an external USB port to allow downloading of data for secure storage or distribution in pdf and other formats. Wired or wireless ethernet and SCADA capability are optional. Insight HD has been developed specifically to meet the needs of the food and packaging industries where good manufacturing practice requires traceability, ef-

Measure your process & do something about it

ficiency, product quality and compliance with existing

With modern technology valves are transformed.

as well as forthcoming regulatory requirements.

Seamlessly integrated positioners, feedbacks, pilots,

The units are available in single- or multifrequency format ranging from 30 to 875 kHz. The Insight HD’s

network interfaces or integrated PID process controllers have opened limitless possibilities in process control.

compact dimensions make it suitable for integration with all well-known checkweighers and for mounting onto new or existing conveyors. JW Industrial Instruments Pty Ltd

We make ideas flow www.burkert.com.au | 1300 888 868

Contact info and more items like this at wf.net.au/M224

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PROCESSING

Filters provide sweet success for Norwegian honey producer

Founded in 1927, Norwegian-based company Honningcentralen is a key player in the production and distribution of honey, and has experienced steady growth over the years. As part of the company’s continued aim to supply good quality honey, a metal-edge industrial filter with a 63 micron wedgewire screen was built into the new production line to remove foreign bodies such as wax and bee wings from the honey. The existing filter was inefficient, continually requiring manual cleaning resulting in downtime and loss of production time. Recognising that they were losing valuable time and profitability from this process, Honningcentralen sought to find a solution. Russell Finex was recommended by Honningcentralen’s subsidiary COMPONENTS office in Sweden. “Our sister company in Sweden had an industrial filter from Russell and they were very happy with it,” says Hege CONTROL Bjørnbakk, Production and Quality Manager at Honningcentralen COMPONENTS in Norway.

Drawing on their experience in dealing with honey, Russell Finex assessed the requirements of the company and recommended an industrial filter from the Self-Cleaning Russell Eco Filter range. With its easy-clean design, the filter is simple to assemble and disassemble without the need for tools. This is a particularly useful feature for the company due to the characteristics of each strain of honey requiring a different screen size. With a more accurate filter screen and its SpiroKlene wiper system, this self-cleaning industrial filter has successfully eliminated the problems previously experienced by Honningcentralen. The SpiroKlene system continuously cleans the surface of the filter element, meaning frequent blockages are no longer occurring. In addition, the pressure problems they were experiencing have been eradicated as oversize material can be manually discharged. Following the successful installation of the filter, Honningcentralen also purchased a Filter Management System. This system automates the discharge of the oversize material from the filter, eliminating operator involvement and increasing productivity even further. Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/M241

Control Components Control Components

Hygienic solutions?

Flow, Level & Pressure

CONTROL COMPONENTS Control Components

Switch to Sitron

Vane anemometer Lutron has released a vane anemometer with a wide measuring range from 0.3 to 35 m/s (reads in five different

Process Sensors for Food & Beverage

units) plus air temperature. In addition, the instrument incorporates a J/K thermocouple thermometer function with mini plug input for standard

Sitron Flow, level & PreSSure SenSorS • Sanitary Designs • No moving parts – longer life • AC, DC and Universal powered models • Relay or Analogue output available • Tri-Clamp, threaded & flanged connections

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The handheld instruments have a data logging to SD card, and data is able to be read from the card and analysed using a normal PC spreadsheet program. No new software to learn, no cables - just plug the card directly into a PC. The data logging can be automatic real time with intervals from 1 to 3600 s with unlimited records or manual by push-button to a total of 99 readings. For users wanting specific PC software, there is a USB interface cable and PC software to download and view data in a

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probes.

33 years of experience in Food & Beverage

more traditional way. ECEFast Contact info and more items like this at wf.net.au/M236

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IP67 I/O encoders Posital has introduced improved Profinet I/O encoders which, according to the V4 profile, support IRT, RT and NRT data transfer (isochronous real time/real time/non-real time). The revised encoders feature an Ertec200-based platform and reach cycle times as low as 1 ms (IRT) and 10 ms (RT). With a diameter of 58 mm, the devices are very compact. A connection cap is

Stainless steel high-pressure water blaster

they can be used in applications with limited installation space. The encoders

Aussie Pumps has released an addition to its Scud range.

are available as hollow and solid-shaft versions. They feature an integrated IRT

The stainless steel Aussie Scud high-pressure water blaster has

compatible switch which facilitates wiring and allows users to save expenses

been designed specifically for cleaning in corrosive environments.

for external hardware.

The latest version has pressures up to 4000 psi and flows up to

Like all Optocode encoders, the Profinet I/O models use an optoelectronic

21 L/min. The heart of the unit is a ‘Big Berty’ Bertolini triplex

scanning method to record position values. The single-turn sensor provides a

pump, running at 1450 rpm and driven through a close-coupled,

resolution of 16 bits per revolution. Additionally, a maximum of 16.384 revolutions

fully enclosed gearbox. The machine comes in the Aussie Scud

(14 bits) can be registered in multiturn mode, thereby covering a measuring range

frame, with four off-road pneumatic tyres with heavy-duty bear-

of 30 bits. The encoders are suitable for use in packaging technology or standard

ings for easy mobility.

machine construction applications. Migration of existing Profibus systems to the

The company has also launched a 5000 psi fully stainless

new standard is easily possible, since the device profile management has been

steel hot water hose reel. Capable of taking up to 45 m of high-

retained. Further equipment includes two M12 connections for data transfer, one

pressure hose, the Hydrotek HAR150 is hardy and versatile.

M12 connection for voltage supply and six LEDs for bus diagnosis. Designed

A wide range of quality high-pressure accessories, designed to

for a -40 - +85°C temperature range, the units provide IP67 protection on the

cut labour costs, reduce times and decrease running costs, are

housing side and IP64 on the shaft side (an optional sealing ensures IP67).

an integral part of the Scud package. These include flat-surface

All Optocode encoders operate without backup batteries and instantly provide

cleaners, portable drain cleaners, high-pressure hose reels, turbo

current absolute position values without referencing even after power failure.

lances, grit blasters and telescopic extension wands.

Plant Control & Automation

Australian Pump Industries Pty Ltd

Contact info and more items like this at wf.net.au/M211

Contact info and more items like this at wf.net.au/M220

ABN: 48 063 847 432

• Various models to meet your production requirements. (High & Low Care Seperable.) • Product that can be packed off as soon as it exits the unit. • Able to cook Pasta, Rice,Vegetables & even Seafood.

VORTEX, COOK, QUENCH & CHILL Vortex Mono A single frame cook, quench & chill system for Pasta, Rice,Vegetables & Fish, delivering output levels of up to 1800 kg per hour. Ideal for companies who are currently manually cooking products and require an automated process to increase output and quality. Mounted on a single frame the Mono is easily integrated in to existing production facilities, and will increase product throughput by automating the cooking process.

Vortex 2 The Vortex 2 is a dual frame cook, quench & chill system for Pasta, Rice,Vegetables & Fish, delivering output levels of up to 2400 kg per hour. Developed for companies cooking high volumes of products, and require a system which will deliver outstanding performance, control and quality. Vortex 2 consists of a series of baskets arranged in line with a high / low risk divide. With a huge range of options available, the system can be tailored to suit your exact requirements and meets the strict demands of the UK supermarkets

DFC Food Systems Pty. Ltd. 20 Summit Road, Noble Park, Vic 3174. - Tel: +613 9701 2000 - Fax: +613 9701 2022 - Email: sales@dfc.com.au

www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

for address allocation. Being shorter than most industrial ethernet encoders,

not necessary and the encoders do not require terminating resistors or switches

Hands-free tapware Hands-free, automatic shut-off, electronically actuated tapware helps facilities deliver high levels of hygiene water savings and cross-infection control. The Enmatic range of hands-free

PROCESSING

Indicator light for washdown environments

tapware from Enware-Oras features a reliable infrared sensor that activates the water flow and auto-focus beam incorporating triangulation technology for more reliable operation.

The Banner Engineering K50L Sealed

Another feature of the range is the optional temperature adjuster, which gives

Audible Ez-Light is a rugged, cost-effective and

users the ability to wash the hands or face with warm water or brush teeth with

easy-to-install indicator light with an audible

cold water, with the added luxury and hygiene of hands-free operation.

alarm, which allows it to be easily seen and

The temperature of the water mix is adjusted simply by rotating the knob on

heard from a distance. Featuring a fully sealed

the side of the tap, turning it towards the front of the basin for a colder mix

body, rated IP67 or IP69K depending on the

and vice versa.

model, the indicator light is suitable for use

The range is WaterMark approved, with a 6 Star WELS rating for water effi-

in the food and beverage industry, processing

ciency. The internals are IP67 rated for water and humidity protection of electrical

lines and areas prone to high levels of moisture.

components, while the range has dual fixing points for extra strength in public

Additionally, with a wide, 12-30 VDC operating

washrooms. There are mains- or battery-powered options.

range, the K50L Sealed Audible is suitable for use in mobile equipment. The K50L is a compact device that is com-

Enware Australia Pty Ltd Contact info and more items like this at wf.net.au/L142

pletely self-contained, requiring no controller for operation. This eliminates the need for wires, allowing the K50L to be easily installed

Chips and extrusions fryer

in virtually any location. It is immune to EMI and RFI interference and is available in 1-, 2- and 3-colour models with green, red and yellow LEDs. Both the IP67 and IP69K models feature 5-pin Euro quick disconnect with PNP input, while the IP67 model also allows for manual volume adjustment. Micromax Pty Ltd Contact info and more items like this at wf.net.au/M026

Hard bite-style potato chips get their desirable extra crunchy texture from the unique oil temperature profile

Maintenance management via iPad

produced by batch fryers. But the limitations of producing such chips in batches of only a few hundred kilograms

Computerised maintenance management software provider MEX has released

per hour has previously required processors to install

its software on the iPad giving users a new platform on which to manage

multiple batch fryers.

their maintenance. The Work Order software system runs on iPad 1 or 2 and consists of the complete Work Order module of MEX. MEX for the iPad enables operations to have a paperless workflow and increase time efficiency as there is no longer a need be at a desk to enter or receive data. Users can enter data while it is fresh in their minds, which

The Universal Product Cooker (UPC) allows continuous production of over 800 finished kg/h of chips - hard bite, medium and soft textures - plus many other types of chips, pellet and extruded snacks. UPC is claimed to be the only fryer capable of producing batch-style and traditional potato chips continuously. It also

increases data integrity. MEXâ&#x20AC;&#x2122;s software solutions help users increase the efficiency in maintaining

makes chips from corn, plantain, banana, taro and other

assets. The software helps users record preventative maintenance, maintain

root crops, multigrain ingredients, plus certain pellet and

work order data and scheduling, monitor labour productivity and reduce

extruded snacks. UPC can even produce traditional-style

equipment downtime.

potato chips with little or no slice washing.

Maintenance Systems Consolidated Pty Ltd

Heat and Control Pty Ltd

Contact info and more items like this at wf.net.au/L472

Contact info and more items like this at wf.net.au/L347

Jan/Feb 2012

www.foodprocessing.com.au

The cradle-to-grave carbon footprint measurement of a particular tipple is an important part of VnC Cocktails’ business mix. With an increasingly worldwide market, the New Zealand exporter wanted to keep an eye on its carbon footprint and ensure existing and potential customers that its cocktails were not just cool, but sustainably cool too.

EMARS, the Certified Emissions Measurement And Reduction Scheme, gave VnC an internationally recognised certification to prove it had measured and reduced the carbon footprint for its business and products. VnC’s entire product life cycle was assessed, from the growing of the fruit used, to the production of its cocktail mixes and freighting to stores, all the way through to disposal of the containers. It’s called a cradle-to-grave measurement, which in VnC’s case included everything from raw materials to human consumption. VnC Cocktails Marketing Manager Alex Badger describes how the company approached the undertaking. “We started with the ingredients. So, for example with the apple juice, we measured the emissions related to the culturing of the apples, making the juice at the press and the transport to VnC’s cocktail production sites.” Packaging was next under the microscope. Bottles, labels, caps, cartons and the rest were assessed for emissions related to production, including electricity and water usage, waste, natural gas, refrigerants, fuel and even required staff travel. “The finished product is then shipped to domestic or overseas retailers and hospitality businesses. Our measurements also included the emissions cost of chilling, shelving and lighting in these outlets,” says Badger. The life cycle measurement ends after the disposal of the cocktail packaging. Badger says CEMARS certification is a vital part of VnC Cocktails’ business mix: “Having CEMARS certification will give us a competitive edge, particularly in markets such as Europe and the United Kingdom.”

www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

VnC Cocktails stirs sustainability into its mix

PROCESSING CEMARS streamlines the process for exporters to achieve credible greenhouse gas certification. Graham Carter, Chief Executive of carboNZero Holdings - which developed CEMARS as an alternative option to its carbon neutral certification - says more and more countries are either already legislating ways to measure carbon footprints of imports or looking to do so in the near future. Even global retail giants, like Walmart and Tesco, are throwing their weight behind such requirements. “They’ve drawn a line in the sand,” Carter says, “‘show us a carbon label or a carbon scorecard, or we won’t show you our shelves’.” CEMARS product certification provides an opportunity for companies to demonstrate a commitment to the measurement and reduction of their products’ emissions before, or instead of, a carbon neutral achievement. “It also makes economic sense,” Carter says. “Cutting emissions will result in cost savings and in most cases this outweighs the cost of obtaining the certification. A certified emissions measurement and reduction claim can also add value to a company’s brand and increase market access.”

Businesses in search of a product certification that’s transparent, based on a scientific footprint measurement, aligned with international best practice (PAS 2050 and ISO 14067) and developed by the world’s first internationally accredited greenhouse gas (GHG) certification scheme need look no further than CEMARS. Now businesses in Australia can attain CEMARS through LRQA, a global businesses assurance firm that assists clients to access markets, increase sales and improve efficiencies through independent certification. Recognised by over 45 accreditation bodies and delivering services to clients in more than 120 countries, over half of the world’s top companies choose LRQA for its unique insight into global markets. LRQA is a member of Lloyds Register Group, which has a 250-year history working with over 45,000 clients in key sectors of food, packaging, manufacturing, transport, energy and marine.

Lloyd's Register Quality Assurance Contact info and more items like this at wf.net.au/M188

Nitrogen analyser for food and feed analysis The Velp Scientifica NDA 701 Dumas nitrogen analyser is a simple-to-use, rapid and cost-effective instrument designed to measure protein in food, grains, animal feeds and soil. The NDA701 measures nitrogen by combustion and detection using a thermal conductivity detector. A built-in, 30-cup autosampler that can stack four carousels allows uninterrupted operation for up to 116 samples. Typical analysis times are 3 min/sample and samples up to 1 g can be measured. The Velp DUMASoft software is simple to use and provides complete control and data reporting. The NDA701 uses helium as a carrier gas to give the greatest sensitivity. The system has two inline moisture traps to prolong the life of the oxidation tube furnace, thus reducing the operating costs per test. Next Instruments Pty Ltd Contact info and more items like this at wf.net.au/L276 24

Jan/Feb 2012

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IP66-rated computers Designed and manufactured to protection standard IP66, APC Technology’s FT units are fully sealed, rated to 60°C and are available with sealed connectors to eliminate all This prevents the build-up of debris and waste, making the rugged computers a solution for hot wash applications and processing environments where dust and liquids are present. Human interface options include: touch screens, keyboards and pointing devices. Units can be custom designed to accommodate specific hardware and software requirements for particular processing environments. Options include stainless steel construction and a shatter-proof fascia. The FT series platform is suited to monitoring and control applications within abattoirs, meatworks, livestock management, dairy facilities, milk production, phar-

The Haydon Kerk G4 36 mm linear actuator is claimed to have a 20% higher output force that allows the 36 mm to replace larger 42 and 46 mm units. It includes a special adaptor plate to allow ‘drop-in’ replacement of larger units. More power in a smaller physical package is of great benefit where space is critical and the 36 mm unit offers a price advantage of the larger units. When replacing a larger unit, the adaptor plate allows the G4 to be mounted using the same bolt pattern, which simplifies installation of the upgrade. Force output for the G4 is from 70 to 260 N and the unit is available in three configurations: captive, where the screw is held from rotation by the actuator; non-captive, where the screw drives through the motor; and external linear, where the motor drives the screw

maceutical manufacturing and bottling processes.

with the load nut running externally on the screw.

APC Technology

Treotham Automation Pty Ltd

Contact info and more items like this at wf.net.au/L194

Contact info and more items like this at wf.net.au/M059

www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

gaps and surface collection points.

Linear actuator

Inline fat analysis plus contamination detection The Eagle FA 720 PRO fat analysis system provides a noninvasive and accurate inline method of fat in meat analysis with 100% inspection. Based on dual energy X-ray absorptiometry (DEXA) technology, the system accurately produces chemical

PROCESSING

lean (CL) values within Âą1CL. The accuracy of the measurement combined with its good inspection capabilities provides meat producers with a tool to prevent product giveaway and eliminate claims on fat content. In order to determine fat levels, the FA 720 PRO uses two energy spectrums to discriminate between high- and lowchannel X-rays. By evaluating the ratio of energy absorbed at a high spectrum to the level of energy absorbed at a lower spectrum, the technology infers the average atomic numbers of the product scanned to provide an accurate and reliable CL value. Further, the inline system performs real-time scanning to allow manufacturers to quickly verify that incoming and outgoing meat, either in bulk or hygienic storage E2 size crates, is within specification - allowing for total control without disruption to output levels. Since X-ray cross-section absorption in the high energy beam is proportional to weight, the system can checkweigh products to better than 1.5% dynamic accuracy, independent of vibrations and air current. To ensure compliance, the system features Eagleâ&#x20AC;&#x2122;s intuitive management software, barcode readers and trace servers to allow quality personnel to remotely access real-time data and reports for production, rejection, weight and trending. This is especially important considering new regulations calling for traceability through every stage of a productâ&#x20AC;&#x2122;s life cycle. Meat products now need to be effectively catalogued and product tracking information is simple and easy to access. A multifunctional machine, the FA 720 PRO can simultaneously inspect for metal, stone, glass and bone contaminants. The system not only monitors fat content of meat products, it can also detect foreign objects and check mass at speeds of up to 145,000 kg of bulk or carton meat per hour.

Oil-free compressed air Boge has launched the BC series converters that are claimed will cost-effectively assist users to efficiently produce absolutely oil-free compressed air to Class 0 (ISO 8573-0) quality. In industries such as the PET sector, the food and drinks sector, and the pharmaceutical and chemical sector, generating absolutely oil-free compressed air is paramount. One way to generate oil-free compressed air is to use an oil-free compressor. However, this can be an expensive option and quite often is only feasible for large compressed air users. The BC series converters provide a solution for efficiently and cost-effectively generating absolutely oil-free compressed air. The BC Converter is installed directly downstream from the compressor and has been designed to make downstream oil penetration impossible. Due to the catalyst system, the Boge converter only produces ultraclean condensate and absolutely oil-free compressed air according to quality Class 0 (ISO 8573-0). The catalyst system ensures the long hydrocarbon chains of the residual oil contained in the compressed air are split up into carbon dioxide and water - substances which are naturally present in the atmosphere. The catalyst material is stored as granulated and compact bulk material in a receiver and compressed air circulates around it. Simultaneously, both oil droplets and oil vapours are cracked, which

Food Equipment Australia

means that both compressed air and any resultant condensate are

Contact info and more items like this at wf.net.au/M232

absolutely oil free. The advantage for the user is a cost-effective solution to generating oil-free compressed air with both purchase and operating costs lower in comparison to running an oil-free compressor with a traditional treatment system. The Boge BC converters are very energy efficient, operating with an extremely low energy consumption level between 0.01 to 0.005 kWh/Nm3. Additionally, with no filter pressure loss either, operating pressure can be optimised. With a service life up to 20,000 operating hours, maintenance requirements are kept to an absolute minimum. Additionally, because the converter does not require filtration, subsequent element changes are eliminated. The Boge BC Converters are available in 13 models. Boge Compressors Ltd Contact info and more items like this at wf.net.au/M057

Jan/Feb 2012

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Interlocking guard system The Eichner MGB (multifunctional gate box) is an interlocking guard system for the protection of safety doors on machines and systems. Linked to machine controls, the opening of the access The device features an integrated lockout mechanism with optional escape release handle,

Ultrasonic liquid flow meter The GE Panametrics PT878 ultra-

and optional buttons and indicators can be integrated directly into the housing. The unit is easily

sonic liquid flow meter has been

mounted on frames, grilles or profiles, and the handle can be mounted level or rotated 90, 180,

added to TechRentalsâ&#x20AC;&#x2122; extensive

270Â° without disassembly. Start, enable, emergency stop and other functions can be added to

test and measurement rental fleet.

the basic handle/lock module to turn it into a small control terminal. This enables the unit to be

The ultrasonic liquid flow meter

used for interlocking, guard locking, escape release and machine functions such as start/stop,

measures flow rates without cut-

emergency stop, etc. The modular design means that additional features can be easily added

ting the pipe and comes with a

at a later date. Even the basic system complies with safety Level E in accordance with EN ISO

built-in data logger for 100,000

13849-1 or SIL3 in accordance with EN 62061, and EN 1088 for protection against tampering.

measurements.

An LED display provides continuous information on system status.

The GE Panametrics flow meter

The optional escape release is intuitive to operate and enables persons to exit the danger

features a non-invasive clamp-on

area quickly and easily. When working in the restricted area, the bolt tongue can be locked open

transducer and a flow range 0.03

with up to three padlocks in the integrated lockout bar, preventing unintentional activation of the

to 12.2 m/s.

interlocking/guard locking. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/M070

TechRentals Contact info and more items like this at wf.net.au/L289

www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

door via the MGB will be prevented until the machine has safely stopped.

PROCESSING

Ten key signs that new Integrated business systems should be as much a fundamental part of a modern food company’s operations as quality manufacturing equipment or well-trained personnel.

owever, food industry software specialist Graycorp said there has been reluctance by some companies to make the required investment in quality software up until the past couple of years. “While many of the food industry businesses we have spoken with are very focused on production and plant innovation, there tends to be a view that IT is somewhat of a ‘necessary evil’, rather than the valuable asset that it can be,” said Graycorp Managing Director Lachlan Gray. “Expenditure on IT is often seen as a cost by business owners, rather than an investment in the efficiency of the business. We talk a lot with clients and potential clients about how their IT systems can be an important part of the business growth strategy.

Lack of integration and visibility across the business. “It is not necessarily functions that some food businesses are lacking, but rather the efficiency of the functions,” Gray said. “Our experience with numerous food industry companies (ranging in turnover from $1 million to more than $100 million) is that the main need is to increase real-time visibility across the business. “There tends to be a lack of integration between the various business functions, which leads to silos of information forming and making it difficult to obtain a holistic and up-to-date view of the business.” Furthermore, due to the fact that it generally requires considerable manual effort to duplicate and consolidate information, there is also the added risk of data handling errors.

Critical business information sits with personnel. Many businesses have their critical business information and intellectual property - such as recipes or procedures - sitting in the heads of one or a few key personnel. This is highly dangerous should something happen to these people or they leave the business. This critical information needs to be contained within the systems of the business so that they can be adequately backed up and accessed, as required, by others.

Jan/Feb 2012

www.foodprocessing.com.au

“Pleasingly, in recent years there has been a growing recognition of the value well-planned, integrated software solutions can add as part of the investment in IT.” If a business has grown consistently in recent years, or there hasn’t been any significant investment in software in the past five years, Gray suggests it is highly probable that the systems being used are outdated and not keeping pace with the needs of the business. Graycorp suggests there are 10 signs that a business has outgrown its existing systems: the true gross margin by product and by customer. “This is even more important for companies that export their product overseas and are finding their profits being eroded as a result of the high Australian dollar,” Gray said.

Decision-making is reactive rather than proactive. Because it can take days or even weeks to access up-to-date information about what’s happening in the business, decision-making by the business owners and management tends to be reactive rather than proactive, putting a great deal of pressure on the whole organisation. “Entering data today so you know what you did yesterday is like trying to drive forward by looking in the rear-view mirror,” Gray said.

There is a lack of understanding of the business’s true costs. In an increasingly competitive marketplace where margins are being squeezed, it’s imperative that users have a complete understanding of the true costs of running their business. Furthermore, it is imperative that they can easily determine the true gross margin by product and by customer. “This is even more important for companies that export their product overseas and are finding their profits being eroded as a result of the high Australian dollar,” Gray said.

The company doesn’t have the capacity to interact with suppliers and customers electronically. One way food companies can achieve real operational efficiencies is by considering having their software systems integrated with those of their key trading partners. “If you can have visibility over what your trading partner is doing and they can have visibility over what your demand or needs are, it’s going to provide efficiencies for all,” Gray said.

The business is growing but isn’t any more profitable. “If your business has grown significantly but the bottom line has not increased proportionately, the chances are your systems are not working for you,” Gray said. “So despite the extra work and risks associated with running a larger business, the rewards might not justify the extra effort. “Appropriate software systems should be able to handle the increased production of the business and allow the optimal use of existing resources without associated additional costs.”

The company regularly has short supply or is out of stock on products. Without a clear picture of the forward requirements for production and purchasing, manual systems may result in the business being unable to supply product to meet customer demand, undermining your sales opportunity and supply reputation.

Additional administrative staff are required to handle the workloads. With a growing business comes an increased administrative burden. If there aren’t integrated, business-wide systems in place, this can often result in the need to hire additional administrative staff to handle the associated workloads.

Large amounts of stock are regularly written off. Manual systems which don’t provide the scope to efficiently track production and provide batch control often result in large amounts of stock being written off because sell-by or expiry dates have been passed, particularly those products with a short shelf life.

Opportunities for growth or expansion are not being pursued. “In addition to inefficiencies, one of the consequences of not having integrated systems is lost opportunities for profitable growth and expansion,” Gray said. “Without access to core information about their business, business owners and managers are often scrambling to manage the day-to-day operations. As a result, there’s little or no time for the planning of new products, additional market opportunities or expanded distribution channels. “Having access to an integrated system that provides real-time reporting across the whole business, and therefore complete transparency, is essential for food businesses to ensure they can supply their customers in a timely manner, meet stringent quality control requirements and capitalise on opportunities for growth,” Gray said.

Graycorp Pty Ltd Contact info and more items like this at wf.net.au/M019

www.foodprocessing.com.au Jan/Feb 2012

PROCESSING

systems are needed for food companies

Human-machine interfaces The Allen-Bradley PanelView Plus 6 range of humanmachine interfaces (HMIs) is designed for applications that require monitoring, controlling and displaying information in dynamic ways, where operators must quickly understand machine status in order to make

PROCESSING

better decisions.

Configurable safety relay systems Additional base units are now available for Pilz’s configurable safety relays PNOZmulti Mini. These enable quick, easy connection of communication and safe link modules, as well as contact expansion modules. As a result, interlinked and decentralised plants can now also be monitored safely using PNOZmulti Mini. Communication and safe link modules are available for the expandable base units. The communication modules are designed for connection to Ethernet TCP/IP and Modbus TCP and have a serial interface. The expandable base unit PNOZ mm0.2p also provides an integrated multilink interface. The base units are easy to configure using the PNOZmulti Configurator software tool. The safe link modules enable data to be exchanged be-

Recently introduced terminals - ranging in screen

tween multiple PNOZmulti Mini base units and also between

size from 18 to 38 cm - feature more memory with

PNOZmulti Mini and the control system PNOZmulti. Sensor

faster refresh rates and more on-device storage.

technology can also be connected outside the control cabinet:

A memory increase from 64 to 512 MB supports

up to four decentralised IP67 modules can be connected. As

graphics enhancements along with larger application

a result, all safety functions can be monitored not just safely,

runtime files, expanding the terminals’ capacity to handle

but directly in the field. The safe link modules are designed

demanding applications.

up to PLe in accordance with EN ISO 13849-1 and SIL CL 3

An increase in processing speed from 650 MHz to 1 GHz enables operators to get to the screens and

in accordance with IEC 62061. The expandable PNOZmulti Mini is particularly suited for use in safety systems which have a high number of distributed process plant items such as in the FMCG, food and beverage,

data faster, avoiding errors and improving their ability to respond. Other PanelView Plus 6 enhancements include re-

packaging, and pulp and paper industries.

mote monitoring utilising built-in VNC and FactoryTalk

Pilz Australia Industrial Automation LP

ViewPoint server; built-in PDF viewer for user manual

Contact info and more items like this at wf.net.au/M027

and troubleshooting guides; remote recipe and data management with ability to save data in .csv format; built-in Arial Unicode font to support multiple languages

Temperature probe range The Hygienic Pt100 sensors with 4-wire connection have been added to ifm’s temperature probe range. Features include: available as probe sensor or with integrated Tri-Clamp process connection; probe diameter 6 mm; robust stainless steel housing with IP68 and IP69K protection ratings; high-pressure resistance for different application areas; and precise temperature measurement using a Pt100 sensor element, class A. The types TM48 and TM49 need no separate hygienic process adapter. They are directly fitted with a 1...1.5″ or a 2″ clamp process connection. The TTx291 version can be easily fixed using clamp fittings.

with a single run-time application; and greater connectivity to peripherals (such as USB memory, printer, mouse, keyboards). The PanelView Plus 6 includes the latest FactoryTalk View Machine Edition (ME) and FactoryTalk ViewPoint software running under the Windows CE 6.0 operating system. Windows CE 6.0 delivers added security and reduced corruption in a closed system that does not require a shutdown procedure. EtherNet/IP is the standard network.

The 6 mm thin sensor tip provides a fast response time of T05 = 1 s and T09 = 3 s while ensuring high stability. The sensor has a high protection

Rockwell Automation Australia

rating of IP68/IP69 K and surface definition, making it suitable for use in hy-

Contact info and more items like this at wf.net.au/M060

gienic applications. ifm efector pty ltd Contact info and more items like this at wf.net.au/L679 30

Jan/Feb 2012

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Food pairing and shared flavour compounds These flavour compounds are shared in popular ingredients like tomatoes, parmesan cheese and white wine. Authentic East Asian recipes, on the other hand, tend to avoid mixing ingredients with many shared flavour compounds, according to new complex networks research from Indiana, Harvard, Cambridge and Northeastern universities.

n a search to uncover the patterns and principles people use in choosing ingredient combinations beyond individual taste and recipes, a team that included Indiana University Bloomington School of Informatics and Computing Assistant Professor Yong-Yeol Ahn looked at the key ingredients of 56,498 online recipes and then analysed those ingredients for shared flavour compounds. The recipes came from three online recipe repositories: epicurious.com and allrecipes.com from the US and the Korean menupan.com. Over the past decades, some food scientists and chefs have developed a food pairing hypothesis which states that ingredients sharing flavour compounds are more likely to taste good together than ingredients that do not. Some application of this can be found at contemporary restaurants that successfully pair white chocolate and caviar, ingredients that both contain trimethylamine and other flavour compounds, or chocolate and blue cheese, which share at least 73 flavour compounds. Ahn, who is also affiliated with the Center for

Complex Networks and Systems Research operated by SOIC and IU’s Pervasive Technology Institute, said that by creating a flavour network that captures the flavour compounds shared by culinary ingredients, the team could reformulate the food pairing hypothesis into a hypothesis on the graph-topological properties of recipes in the flavour network. Statistical tests can then be used to unveil the connectedness, or the lack thereof, of ingredients and flavour compounds. In this case, they took 381 ingredients from the group of recipes, along with an associated 1021 flavour compounds that contributed flavour to those ingredients, and created a flavour network where ingredients are connected if they share at least one flavour compound. “What we showed was that the recipes in North American cuisine tend to share more flavour compounds than expected. The most authentic ingredient pairs and triplets in North American cuisine also tend to share multiple flavour compounds, while compound-sharing links are rare among the www.foodprocessing.com.au Jan/Feb 2012

INGREDIENTS AND DEVELOPMENTS

Western cultures love a good mix of α-terpineol, 4-methylpentanoic acid and ethyl propionate for dinner.

INGREDIENTS AND DEVELOPMENTS

Each node denotes an ingredient, the node colour indicates food category, and node size reflects the ingredient prevalence in recipes. Two ingredients are connected if they share a significant number of flavour compounds, link thickness representing the number of shared compounds between the two ingredients. Adjacent links are bundled to reduce clutter.

most authentic combinations in East Asian cuisine,” Ahn said. Their analysis also referenced that the number of actual recipes in use, on the order of about 106, was tiny when compared to the large number of potential recipes (over 1015). “We identified frequently used ingredients that contributed positively to the food pairing effect in North American cuisine, like milk, butter, cocoa, vanilla, cream and eggs,” Ahn said. “These played a disproportionate role, as 13 key ingredients that contributed to a shared compound effect were found in 74.4% of North American recipes.” There were also ingredients in East Asian cuisine - beef, ginger, pork, cayenne, chicken and onion - that were the top contributors to an overall negative shared compound effect on food pairing. One future goal of the research would be to build an accessible infrastructure using more detailed datasets that incor-

porate the quantity information of flavour compounds, again advancing the use of data-driven network analysis methods that have transformed biology and the social sciences to yield new insights into food science. Another interesting venue of research is studying the evolution of recipes. A recently published recipe-evolution model suggested that the staple ingredients consist of old ingredients (founders) and highly ‘fit’ ingredients. “Among highly prevalent ingredients, we can see old ingredients that have been used in the same geographic region for thousands of years,” Ahn said. “Yet there are also relatively new ingredients like tomatoes, potatoes and peppers that were introduced to Europe and Asia just a few hundred years ago. Though new, they are now staple ingredients.” ‘Flavour network and the principles of food pairing’ was published in Scientific Reports in December 2011.

Natural meat tenderiser Cuisine Resources OT1005X Kiwi Fruit Powder Extract (KFPE) is a 100% natural meat tenderiser which is suitable for use with various cuts of meat, poultry and seafood products. KFPE OT1005X has been developed to overcome the problems meat processors face, namely the unreliable quality of many cuts and the long times needed to achieve satisfactory levels of tenderness. Derived from fresh green kiwifruit, the extract’s active component is the natural protease enzyme actinidin, which is mainly found in this fruit species. The extract is manufactured in New Zealand using a proprietary process without chemicals or solvents. As the final extract is standardised, its activity level is consistent and unaffected by seasonal variations during the growing season. Unlike any other natural protease enzyme, such as papain or bromelain, KFPE OT1005X has a temperature activity range of 2°C and deactivates at approximately 38°C. It reaches peak activity at 20°C. The natural extract tenderises at low temperatures while also keeping micro loads at low levels. The extract is acid and salt tolerant, and compatible with phosphates and spices. KFPE OT1005X is designed to tenderise and then consume itself so there is no need for elevated temperatures to kill the activity. This ensures that there is no live enzyme present when the treated meat cut reaches the marketplace. Ingredient Resources Contact info and more items like this at wf.net.au/M058 32

Jan/Feb 2012

www.foodprocessing.com.au

New Look

The Mecmesin FTA 2.5 Xt Food Texture Analyser is based on the Mecmesin MultiTest 2.5 Xt, a 2.5 kN

HI93501NS digital thermometer

test centre for tension and compression.

$188

The FTA 2.5 Xt is controlled by a Windows 7 Tablet PC, directly connected to the testing centre

plus gst

to control the machine and capture the data. The FTA 2.5 Xt can be preprogrammed for routine testing and it is possible to select up to five of these tests as â&#x20AC;&#x2DC;favouritesâ&#x20AC;&#x2122;, which allows operators to load their test with one press of the button, ready for testing. In-depth and advanced routines can be programmed and the analysing part of the software enables in-depth analysis of food texture properties such as chewiness, firmness, hardness and softness of food products. Special probes and fixtures, such as the Kramer shear cell, dough and gluten test cell and a variety of accessories are available for all food products. SI Instruments

HI2211 bench pH meter

$658

plus gst

Contact info and more items like this at wf.net.au/L195 HI96821 refractometer for NaCl

$255

MAP gas mixture monitoring

plus gst

Modified atmosphere packaging, MAP, is a key method to maintain the quality and improve the shelf life of processed and fresh meat products. Ensuring that the correct gas mixture is in the packaging is a crucial requirement of the process, so the mixture must be monitored in a reliable and efficient way. Traditional quality control approaches involve manually removing packages at intervals and test-

HI96801 refractometer for Brix

$255

plus gst

ing them to ensure that the gas mixture is as it should be. This is time-consuming and wasteful.

RESELLER ENQUIRES WELCOME

A far better system involves quality assurance, where the gas mixture is monitored constantly during the flushing and packaging process, so any deviation is immediately identified and can be corrected with minimum disruption to the production line. PBI-Dansensor has a range of inline gas analysers that continuously monitor the gas content of the packaging chamber before the packages are sealed. Pryde Measurement Pty Ltd Contact info and more items like this at wf.net.au/K597

Tel: + 61 3 9769 0666 Fax: + 61 3 9769 0699 Email: hannains@hannainst.com.au www.hannainst.com.au www.hannachecker.com.au www.foodprocessing.com.au Jan/Feb 2012

TESTING

Food texture analyser

for 2012

TESTING

Temperature control system The Julabo range of Presto temperature control systems includes the air-cooled A30 and A40 and the water-cooled W40. The units have been specifically designed for highly precise, temperature control applications as well as rapid temperature changes, making them suitable for reactor vessels, material stress tests or temperature simulations. The range features large heating (2.8 kW) and cooling (1.2 kW) capacities and a wide working

IP67-rated digital thermometer The Hanna Instruments HI

temperature range of -40 to +250°C (only requires one bath fluid for the entire working temperature

93501NS is a water-resistant

range). These systems are capable of compensating for exothermic and endothermic reactions

(IP67) thermometer designed for

and work reliably even in ambient temperatures up to +40°C.

daily use in food applications such

Magnetically coupled pumps in the Presto units are powerful and maintenance free. Laboratory

as industrial kitchens and catering.

users benefit from high flow rates, constant pressure and a controlled build-up of pump pressure.

With a measurement range of -50

The pump in the A30 has a rated pressure of 0.5 bar and a maximum flow rate of 20 L/min. The

to +150°C, the meter has an ac-

A40 and W40 have more powerful pumps with pressure up to 1.7 bar and a flow rate as high as

curacy of ±0.4°C. This meter also

40 L/min. The operator can adjust pump capacity by selecting one of five stages or by entering

features a stability indicator bar

a specific pressure. The closed pumping loop isolates the heat transfer liquid from ambient air,

graph and ‘hold’ button to freeze

preventing penetration of moisture and oxidation. Once in operation, the units are quiet.

readings on the LCD.

The integrated 5.7″ industrial grade touch screen provides users with a clear and well-organised

The HI 762PWL penetration

view of important information while improving user friendliness. Fingertip control via the touch

probe is included. A diverse

screen makes the unit easy to operate.

assortment of HI 762 probes

The Prestos have closed side panels without ventilation slits, thereby reducing the overall foot-

and cable lengths are available.

print. A retractable handle and integrated rollers make it easy for one person to move the device.

Probes can be ordered with dif-

John Morris Scientific Pty Ltd

ferent handle colours to prevent

Contact info and more items like this at wf.net.au/L477

cross-contamination. The display indicates the remaining battery power at start-up then continuously checks the battery level and warns the user with

Bifidobacteria enumeration in milk

(BEPS) which alerts the user in

bifidobacteria in milk products.

the event that low battery power

In combination with the selective supplement Lithium-

could adversely affect readings.

Mupirocin (MUP), the TOS Propoinate Agar allows the direct

Additionally, the meter has miss-

detection of viable bifidobacteria in starter cultures and

ing/damaged probe indicators.

various milk products like fermented and unfermented milk,

Users can check the meter’s

milk powder and baby food. The growth of other lactic acid

accuracy at any time with Hanna

bacteria is very much inhibited so that a confirmation of

calibration keys. Simply plug the

presumptive bifidobacteria is in most cases not necessary.

key into the meter’s probe input

The detection of bifidobacteria is done by using the

and if the display value does not

plate count method with an anaerobic incubation at 37°C.

match those of the key, the meter

Standard 29981/IDF 220: 2010. Merck Millipore Contact info and more items like this at wf.net.au/L192 Jan/Feb 2012

The instrument is equipped with a battery error prevention system

TOS-MUP medium is suitable for the enumeration of

The composition of the medium complies with ISO

ample time to change the battery.

www.foodprocessing.com.au

is due for recalibration. Hanna Instruments Pty Ltd Contact info and more items like this at wf.net.au/M217

SwabSURE ListeriaP Direct detection of pathogenic Listeria After sampling with a pre-moistened swab dosed in TSC neutralising buffer and incubated for 24-48 hours, the appearance of a turquoise blue colour indicates a positive presence for pathogen specific Phospholipase C enzyme.

ListeriaP is an innovative colour-change Listeria testing product for environmental and food contact surfaces. This colour change permits differentiation of pathogenic Listeria monocytogenes and Listeria ivanovii from other commensal microorganisms including Listeria innocua.

In tests this highly sensitive and specific method (down to 1cfu/sample) reliably recovered pathogenic Listeria whilst excluding Bacillus spp., Entercoccus spp., Micrococcus spp., Klebsiella spp. and other spoilage organisms by utilising a combination of antibiotics and inhibitory compounds. ListeriaP eliminated the false positives, a common failure with other traditional methods.

SwabSURE ListeriaP

> ISO 18593:2004 compliant system and externally validated by Campden BRI

Self contained test for the presumptive detection of pathogenic Listeria from environmental and food contact surfaces.

> The sampling swabs are coloured blue for clear identification in a food processing environment > The open matrix offered by the foam swab enhances recovery and release of sample, ensuring accurate and confident results every time > The neutralising buffer provides inactivation of QACs, phenols, peroxides and other sanitisers, increasing the viability of the sample > False positives are eliminated by the introduction of a chromogenic media for easy identification of results

For more information please email Haig.Henry@thermofisher.com

1300-735-292 | www.thermofisher.com.au

> Simple and quick to use with no mixing of reagents or multiple steps > Results within 24-48 hours

pH and conductivity measurement Mettler Toledoâ&#x20AC;&#x2122;s Seven pH series now includes a compact line of meters - the SevenCompact range for pH and conductivity measurement. The SevenCompact series combines precise electrochemical measurement with flexibility and ease of use.

TESTING

This intuitive new line includes the pH/ Ion S220 - a multilanguage benchtop meter for pH, ORP and ion measurement, with Intelligent Sensor Management (ISM) technology and 5-point calibration. The Conductivity S230 is a multilanguage benchtop meter for conductivity, salinity, TDS, resistivity and conductivity ash, with ISM technology and designed to meet industry regulations in segments such as bioethanol and sugar. While the instruments encompass numerous measurement parameters and offer many options for data input and archiving, it is also possible to perform straightforward calibrations and measurements with a single key press. Mettler Toledo Contact info and more items like this at wf.net.au/M237

Lactobacillus enumeration Arrow Scientific has available the Aerobic Procedure for Lactic Acid Bacteria test that was developed in collaboration with 3M and Kraft Foods. The procedure enumerates lactic acid bacteria in food and environmental samples by integrating a combination of the 3M Petrifilm Aerobic Count Plate, a pH indicator and MRS (deMan, Rogosa and Sharpe) media. The procedure is suitable for monitoring shelf life and environmental samples for food products, such as raw and ready-to-eat (RTE) meats. While lactic acid bacteria typically do not cause illness if ingested, they can change the colour and flavour of food products. Lactic acid bacteria testing is not mandated by government regulation; however, food manufacturers monitor lactic acid bacteria in products and environments to ensure customer satisfaction. Arrow Scientific Contact info and more items like this at wf.net.au/P254

UV-vis spectrophotometers VWR spectrophotometers are reliable, robust and easy-to-use instruments with a range of accessories for tailoring different laboratoriesâ&#x20AC;&#x2122; needs. They are suitable for advanced measurements and quality control. The application software offers all the important methods

available at

expected from a universal instrument. The spectrophotometerâ&#x20AC;&#x2122;s features include a large LCD, multicell holder as standard, full scanning, high accuracy and precision, in-built memory for ease of use and application software that allows full PC control. Modes include basic, quantitative, wavelength scan, kinetics, multiwavelength and DNA/protein. VWR spectrophotometers are available in three models and with a range of accessories such as electronic thermostated cell holders and sipper units to suit different applications. VWR International Pty Ltd Contact info and more items like this at wf.net.au/M221

Jan/Feb 2012

www.foodprocessing.com.au

PACKAGING & LABELLING

The real and digital worlds of packaging The days are gone when packaging was used for nothing more than protecting the product and ensuring an attractive presentation at the point of sale. These days, packaging has to do a lot more. It has to be intelligent and interactive, and it is supposed to track goods along the entire supply chain, to expose counterfeits, to test whether a package has already been opened or to indicate whether a cold chain has been interrupted. Finally, it is supposed to make it possible to pursue new methods of brand communication and to interact with the consumer.

R (quick response) codes are spreading very rapidly at the moment: in magazines, on placards and on packaging too. More and more merchants and manufacturers of branded products are making use of these two-dimensional codes. If the consumer has a mobile phone with a built-in camera or a smartphone, it can be used to scan in the code printed on the packaging. The phones have an app that decrypts the code and navigates the user directly to the corresponding website of the manufacturer, where consumers can find more information. In this way, the limited analog space on the packaging can be expanded virtually. For example, the stated goal of Frosta, a producer of frozen foods, is to “remove cooking obstacles”. The company prints a QR code on many frozen vegetable packages. With a smartphone, the consumer can then use the code to navigate to a microsite that presents recipe ideas, for example. Any ingredients that are still needed can then conveniently be bought during the same shopping trip. But that’s not all: In keeping with the trend towards interactivity and networking, users can also enter their own recipe ideas and use interfaces to social media networks like Facebook and Twitter.

Using interactive packaging to boost product appreciation Coca-Cola has its sights on a different target group. Together with the can manufacturer Ball Packaging Europe, the beverage maker wants to use beverage cans as a link between music and refreshment. A consumer with a mobile phone uses the QR code printed on the can to connect directly to the Coke Music Portal. “This way, the beverage can appeal to several of the customer’s senses at once - taste, hearing, sight - and therefore turns into an interactive, multimedia amplifier of the customer’s enjoyment of the product,” says Gerlof Toenhake, Director of Marketing at Ball Packaging Europe. QR codes are used for more than just brand communication, however. The printing press manufacturer Heidelberg has developed a technology that protects against product piracy. The products are equipped with security tags. These consist of a pattern randomly generated from copper threads and an associated, unique QR code. The combination of these two elements on the product itself or its packaging ensures a high degree of protection against counterfeits and generates a unique identity www.foodprocessing.com.au Jan/Feb 2012

If the consumer has a mobile phone with a built-in camera or a smartphone, it can be used to scan in the code printed on the packaging. The phones have an app that decrypts the code and navigates the user directly to the corresponding website of the manufacturer, where consumers can find more information. In this way, the limited analog space on the packaging can

PACKAGING & LABELLING

be expanded virtually.

comparable to a human fingerprint for each individual product. With a special app that runs on mobile devices like smartphones, it is easy for the final customer to check the authenticity of the products labelled in this way. The QR code is used by not only manufacturers of branded products but also by merchants. For example, the discount supermarket chain Netto is currently expanding QR coding for its products. Now that all the packaged fruit and vegetable products have been labelled, fresh meat is being tagged with the QR code too. Via smartphone, the customer can obtain information about the origin, quality and nutritional value of the product, in addition to recipes. The spread of QR codes has gained more momentum as a result of the recent E. coli scare and other food scandals. This shows how quickly a technology can become established if it is relatively simple and inexpensive to use. Because of their cost, RFID (radio frequency identification) tags are not yet suitable for the mass market. If prices fall, this could change quickly, however, because RFID technology has the potential to replace the barcode. Radio frequency technology enables non-contact identification, management and tracking of as many products as is desired, throughout the entire value chain and from production to the consumer. The packaging used for high-priced products is already being made with integrated RFID tags as protection against product piracy and theft. New development: RFID plus sensor The Fraunhofer Institute for Physical Measurement Techniques IPM, Freiburg, is going one step further: it has developed special RFID tags in which sensors are integrated into the label.

This means temperature sensors can be used to check whether a cold chain has been maintained, for example. In a different variant, gas sensors measure the concentration of the gas ethylene, which allows inferences to be made about the degree of ripeness of many types of fruit. As the examples show, packaging is taking on a multimedia character and linking manufacturers, the trade and consumers. There is a downside, however: this brave new world of packaging doesn’t yet seem to be fully mature and functionally stable. A study carried out by GS1 (an international organisation that formulates global standards to improve the value chain) and the consultancy GapGemini shows that the product information often is not valid. Over 90% of the information that British market researchers obtained via mobile barcode scanning was incorrect or incomplete. And how will customers react? Thirty-eight per cent of those surveyed said they wouldn’t buy the product if they can’t trust the data they get via their smartphones. So there is still some work to be done in this regard. Health consciousness provides impetus for developments Despite the fact that there are sometimes still problems with the technology and some ‘teething troubles’ that have to be resolved, these difficulties won’t impede the growth in intelligent packaging. Organic and printed electronics in particular have considerable potential to change the world of packaging. The US market research firm MarketsandMarkets estimates that between 2010 and 2015, global sales of intelligent packaging will grow by 8.2% per year to approximately US$24 billion. With a market share of 35%, North America is set to become the largest buyer of active and intelligent packaging. The health-conscious consumer is applying ever-higher standards to food safety. This is likely to add more impetus to the spread of intelligent packaging, particularly in the fields of dairy products, meat, poultry and ready-cooked meals. For further information on Anuga FoodTec, visit www.anugafoodtec.com.

Australian Made Label Applicators

Jan/Feb 2012

www.foodprocessing.com.au

Oxygen valves for meat packaging The Avery Dennison Flexis Oxygen Valve is a multi-level solution to oxygenating meats. The valve provides retailers with greater control over when packaged meat will bloom for placement in display cases. Retailers using the valve method to oxygenate meat receive the products in individual

The O-I 750 mL Lean+Green

trays, each covered with a clear high-barrier lidding film equipped with the two-part

Premium Burgundy wine bot-

valve. The valve’s upper layer, which functions as an integral part of the protective lid-

tle is 26% lighter but retains

ding film, can be clear or printed. When that layer is peeled away, it reveals a second,

its premium look and feel.

permeable layer that permits the entry of oxygen. Packages of meat can be oxygenated

Manufactured at O-I’s

one at a time, allowing retailers the flexibility to pick for the display case any number

Adelaide plant, the bottle’s

of packages that arrived in a shipment. Also, unlike other technologies, once the top

weight has been reduced

layer of the Flexis Oxygen valve is removed it does not require the entire package to be

from 545 to 405 g and is

relabelled. All the labels applied at the meat processor remain intact until the product is

available in antique green

opened by the consumer.

and french green colours. It is produced

The Flexis Oxygen Valve method is also claimed to help facilitate packaging materi-

using narrow-neck press and blow (NNPB)

als savings over alternative methods of packaging meat, such as the use of a ‘mother

technology, which also reduces energy and

bag’. Both the mother bag and an oxygen scavenger are eliminated with the Flexis valve

water consumption while maintaining pro-

method, which requires only that packaged meat be shipped in cartons, not in bags. Meat

portions and premium design cues brand

processors will also see a savings in the amount of gas used when flushing individual

owners require.

packages versus a large mother bag.

The new bottle delivers environmental

Packages equipped with Flexis Oxygen Valves are shipped in cartons, not in bags,

benefits including: a16% reduction in CO2

and therefore lend their respective packages to more stable and efficient storage and

emissions per container; a 16% reduction

transport. More of the product can be stored on a cube and evenly distributed, which

in water per container; and a 9.7% freight-

can help reduce shipping expenses.

efficiency improvement. O-I Asia Pacific Analytical Services Contact info and more items like this at wf.net.au/M158

The underlying permeable layer of the valves looks like a typical label on a package of meat and can serve as a sales stimulus. Avery Dennison Materials Contact info and more items like this at wf.net.au/K645

It takes tried&true passion to create award-winning labels. For over 40 years, consistent and reliable practices have shaped insignia into a leading national label manufacturer. The dedication to delivering quality products and service, coupled with a team of passionate staff, has helped insignia continue producing award-winning labels.* *2010 Gold Medal PICA Print Awards – Flexographic, 2009 LATMA “Best in Show Winner”

Trust your brand with a multi award-winning label supplier – call us for a quote today. Phone: 1300 467 446 | Email: sales@insignia.com.au | Web: www.insignia.com.au

www.foodprocessing.com.au Jan/Feb 2012

PACKAGING & LABELLING

Lighter wine bottle

PACKAGING & LABELLING

Gloss and colour, print mark and reflex sensors for coffee pad filling The Optima Group is an internationally active, mid-sized family company headquartered in Schwäbisch Hall, Germany. It offers industry oriented packaging and filling machines for the foods, pharmaceuticals, chemicals, air and water filters, cosmetics and non-wovens sectors. The systems dose and package liquid and dry foodstuffs (from low viscosity to paste-like, powders and granulates and chunky and flaky products) and fill them into containers. All of the systems have wenglor sensors installed to ensure smooth operations. Design engineer Waldemar Salwasser, was convinced by the user-friendliness and functionality of the sensors when developing the coffee pad filling system. “When we decided to use gloss sensors several years ago, wenglor was the only manufacturer who offered them,” said Salwasser. The wenglor Color Sensor had a number of competitors, but it’s distinguished by a compact format. Optima’s systems are comprised of modules and are matched to individual customer requirements. The little round plastic cups, which are later filled with coffee or tea powder, are set into cavities via a magazine in the CFL2 machine. Filters are then added if required. The next module doses the coffee or other foodstuff into the cups via a funnel. The tricky part, for sales engineer Matthias Roski, involved regulating the quantity of coffee in the funnel with a wenglor sensor to ensure that there’s always enough powder in the filling funnel. “Thanks to the CMOS line array in the CP35 Reflex Sensor for Measuring Tasks, I found a solution for the application,” he explained. The Reflex Sensor measures the fill-level and regulates it autonomously. It functions in accordance with the principal of angular measurement. For this reason, the object’s colour, shape and surface characteristics have practically no influence on measurement results. The output signal of the Reflex Sensor with CMOS line array technology is practically independent of brightness, colour and surface characteristics of the object to be measured. The measured value can be read out as a voltage value within a range of 0-10 V, as a current value within a range of 4-20 mA,

Jan/Feb 2012

www.foodprocessing.com.au

or in digital format via the RS232 interface. A rising or falling characteristic curve can be selected. High speed, speed mode or the high resolution mode can be selected as required. Teach-in, filter functions, an error output and an RS-232 port are included. The measuring range can be selected individually within the sensor’s working range. When the product is filled into the cups, aroma can be added via the liquid dosing unit, if desired. The cups are then advanced to the foil unrolling module, where they’re sealed with a glossy foil. The wenglor Print Mark Sensor detects the position of the foil and reads out a signal as soon as the foil is located at the right position for stamping and application to the cups so that the round lids sit firmly on the cups. The sensors have been specially designed to recognise printed markings. They have a very small spot and use a white light LED with a long service life. Only one sensor is required for the recognition of all colour combinations, as well as differences in brightness between printed markings and the background. The foil which comes from the unrolling module is one single piece, but it may be comprised of several individual foils which are joined by a blank foil. This unprinted joining foil is either red, green or white. These colours are taught in in advance and detected by the wenglor Color Sensor, which prevents the joining foil from being stamped onto the cups by generating a switching signal. The colour combinations can be individually defined, and the type of white light source can be selected as required. wenglor Gloss Sensors then check to make sure that each cup has a foil lid before it leaves the system. Gloss Sensors are capable of differentiating between surfaces with glossy and matte finishes. Due to the fact that the foil lids are glossy, this type of sensor is ideally suited for the application. The degree of gloss is adjustable and is nearly independent of distance. The coffee pads are then automatically weighed. If they fulfil all of the specified criteria they leave the machine, otherwise they’re sorted out. 400 pads are produced per minute in this way. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/L223

Pouch packaging machine The mini doy pouch packaging machine is a simplified version of the stand-up pouch machine. Until now, smaller applications needed to run through larger machines and

and filling attachment.

For over 20 years Bakery Du Jour has established itself as one of the highest quality patisseries of French pastries and breads in Australia. Proudly Australian owned and family operated, the bakery supplies its unique and innovative range of frozen, uncooked, par-baked and frozen-baked products to cold stores and distributors nationally. Bakery Du Jour recently installed another complete packaging system from Emrich Industries. The PFM ZC1 combines a Zenith bagger with the PFM C1 multihead weigher, which is mounted onto the machine. It is capable of running bags of up to 230 x 300 mm in size and with a volume of four litres at speeds of up to 80 bags per minute. “We needed a state-of-the-art bagging line that offered a high degree of flexibility and accuracy and is simple to use,” said Bakery Du Jour Managing Director, Fernando Gaspar. The absence of a gantry reduces the machine’s cost and footprint and also reduces the height, which improves handling of delicate goods. “Space restraints were a particular issue for us and the PFM ZC1 saved a good metre in height over other systems we had seen,” Gaspar added. After an extensive evaluation process the bakery purchased equipment from Emrich which included the integrated solution for both the bagging and the weighing element of a new operation. Gaspar commented: “The machines are expected to provide reliable service and show excellent production speed. Solid construction and good product support from the Emrich team were key in making the decision for the purchase. “We have bought several packaging machines from Emrich and their technical team are always extremely helpful. The fact that Emrich holds machines in stock has enabled us to meet new contract requirements very quickly.”

ADM Packaging Technology Pty Ltd

Emrich Industries Pty Ltd

Contact info and more items like this at wf.net.au/M069

Contact info and more items like this at wf.net.au/M142

up and time. For a cost-saving approach to bagging pre-made bags, this entry-level packaging machine provides a wide variety of applications. It can also be interfaced with other equipment for use with turnkey lines. The mini doy uses multiple detection sensors used at various points in the cycle to ensure correct bag placement. Suction cups are used to open the pre-made bags and the chute lowers allowing accurate product dump into the bag. The sealing bar has a temperature readout with adjustment for temperature control. The operation is simple and effective for all smallto-medium packaging applications, products such as poultry, frozen foods, coffee, fruit and vegetables, biscuits, nuts and cereals. This machine is simple to operate, with the added convenience of being able to change bag sizes and a run time of 20 bpm. Optional elements include a higher IP rate, product settler gas flushing, and date printer

www.foodprocessing.com.au Jan/Feb 2012

PACKAGING & LABELLING

product lines, with the inconvenience of set-

Bakery installs complete packaging system

>>>

Packaging economics

PACKAGING & LABELLING

Pierre Pienaar MSc FAIP, National President Australian Institute of Packaging (AIP) info@aipack.com.au www.aipack.com.au

Jan/Feb 2012

www.foodprocessing.com.au

Packaging NEWS

The name of the game has become one of intense competition, of finding the growth niches within the overall packaging market to make sure that you grow faster than your opposition. The overall packaging market in developed countries may therefore seem to be rather mature and static but internally it certainly is very dynamic. Each packaging material - paper, glass, metal and plastics - and each form of packaging within these segments continuously struggles for its share of this enormous market. But because the total is growing slowly, the industry has come to resemble a zero game where one materialâ&#x20AC;&#x2122;s gain is anotherâ&#x20AC;&#x2122;s loss. This accelerating competition between the different materials has forced a greater emphasis on new technology, new packaging systems and new distribution systems, and these developments are increasingly occurring on a worldwide basis. Two issues have become apparent when we refer to competitive packaging materials. Firstly, materials must have certain characteristics to perform the functions which are required in their use as a packaging material. Some materials are better placed than others and there is normally a comparison of these properties to decide which will perform best under any given circumstances. No one material is perfect and in most cases there is a trade-off of properties to reach a final decision. It is interesting to note that most packaging materials can, through highly scientific means and advanced technological developments, overcome some of their inherent weaknesses to place them in a better competitive position, ie, their toughest opposition. This invariably costs money, which leads to the second point, namely that of the economics of packaging material. Upgrading the product technologically may be a technically feasible proposition but the strong question remains: Is it commercially feasible? And in this respect the commercial realities of a product carry more weight than anything else. The crux of the matter is that customers will only convert to an alternative packaging medium if the conversion results in better bottom line performance. This is a very stable industry, which has grown steadily over many years. It is far less prone to violent swings in the economic cycle, mainly because the major off-take is pitched at the non-durable segment of the market with a heavy emphasis on beverages - alcoholic and non-alcoholic as well as food. Packaging in product distribution is a techno-economic function aimed at maximising sales, while minimising the total overall cost of distribution. It can be regarded as a benefit to be optimised rather than merely a cost to be minimised. Packaging must be considered in relation to four major factors in industry today: materials utilisation, machinery and line efficiency, movement in distribution and management of people.

2011 AIP Scholarship awarded The Australian Institute of Packaging (AIP) awarded the third scholarship for the Certificate in Packaging during the 2011 Cormack Innovation Awards evening. The AIP Certificate in Packaging is an internationally accredited course developed by the Institute of Packaging UK (IoP) and holds recognition in 27 countries. According to Pierre Pienaar, FAIP, National President of the AIP, the scholarship was awarded to Sina Vodjdani who is a third year industrial design student at the University of New South Wales and was a finalist in the 2011 Cormack Innovation Awards. The Cormack Innovation Award scholarship complements other programs initiated by the AIP including the Australian Packaging and Processing Machinery Association scholarship for the Diploma in Packaging Technology and the AIP scholarship for the Certificate in Packaging for the PCA Southern Cross Awards.

DAIRY Process Partners teamed up with Schneider Electric to set up manufacturing plant for yoghurt company five:am in just eight months.

Jan/Feb 2012

www.foodprocessing.com.au

ÂŠiStockphoto.com/Lauri Patterson

Yoghurt concept to functioning plant in eight months

Complete plant visualisation using Schneider Electric’s SCADA package

Tight time frame The significant challenge for five:am was the tight time frame “Schneider Electric had assembled a suite of efficient to set up the manufacturing plant, commence production and devices that automate and optimise production processes to get product on the supermarket shelves. help food and beverage manufacturers reduce inefficiencies “When the contract was signed to produce and distribute and streamline the entire manufacturing process.” our yoghurt within an eight-month time frame, all we had was a 35,000 square foot site located just south of Melbourne, Configuring five:am’s manufacturing plant Victoria,” explained Prior. “Our site had no manufacturing Schneider Electric was selected by Process Partners as its system in place, inadequate airflow and water supply, and turnkey offering could deliver a whole solution to meet all none of the technology needed to of five:am’s needs. The most produce organic yoghurt.” significant element of Schneider Despite the time frame, five:am Electric’s offering was that its “When the contract was signed to produce and distribute wanted to set up a sophisticated automation technologies could be our yoghurt within an eight-month time frame, all we and automated manufacturing configured off-site and installed had was a 35,000 square foot site located just south facility that would not only alquickly on-site, which meant the of Melbourne, Victoria,” explained Prior. low them to produce its organic design and supply of technology yoghurt safely and efficiently, but could happen in tandem. This at the same time offer the flexwas particularly important given ibility needed for future business the short project time frame. endeavours. They also needed to ensure the plant would allow “We needed a supplier that could provide everything as we them to make the highest possible quality product. didn’t have the time to engage and manage multiple different “To do this, we needed a plant far more sophisticated than vendors. Schneider Electric met all our needs from what we other start-ups. Flexibility in our plant is incredibly important wanted from a supplier. They could provide what we needed because it means we can launch new products and expand and this included parts - sometimes at a day’s notice,” comour offering,” explained Prior. mented Francis.

Partnering for success In May 2010, five:am engaged Process Partners, a specialist dairy engineering and process improvement group, to help manage and execute the project. Process Partners’ extensive experience in the dairy process, and particularly yoghurt, provided Prior with the level of skill needed to pull off the challenging project. Process Partners conducted a detailed audit of five:am’s requirements, taking into account its need to produce more variations of the product than what was initially required to meet its March 2011 distribution deadline. From this, Process Partners developed a manufacturing strategy for the plant and worked with five:am to amend and evolve the strategy based on its budget and business objectives. A crucial element of the plant design and strategy proposed by Process Partners was its project partnership approach with Schneider Electric to provide a full suite of automation and control technology. “Schneider Electric’s capabilities and intelligent product range within this area made them the natural vendor to partner with to address the challenges of the project,” explained Michael Francis, Director, Partner Partners.

“Schneider Electric’s products are open and vendor agnostic, meaning they can easily be integrated and adapted with other technologies. They also have functional touch screens complete with visual applications and local integrator support, so are very easy to use and operate,” said Francis. Schneider Electric’s EcoStruxure architecture was leveraged to provide an integrated solution comprising automation and power technologies. The suite of solutions sourced from Schneider Electric included an integrated SCADA package and motor control solutions to ensure motors and drives run in the most efficient way possible. The SCADA package was implemented to provide operators with complete visibility of plant operations. “Inefficiencies, such as motors running unnecessarily when systems malfunction, can easily be identified through the SCADA system deployed in five:am’s plant. This insight is most valuable when fed into the SCADA management system that presents information in an easy-to-digest dashboard. It allows plant managers to have complete visibility of the plant systems and identifies and isolates problems before they have an impact on the product,” explained Francis. www.foodprocessing.com.au Jan/Feb 2012

DAIRY

ntrepreneur David Prior has a unique take on the adage ‘make the most out of your day’. Having started his day at five o’clock in the morning for over a decade, Prior treasures this moment each morning where he feels he can pause and create his day. It was this philosophy that fuelled Prior to capture this ‘five:am-ness’ and bottle it. Prior’s vision was to produce a high-end organic yoghurt under the business name five:am. He also wanted to ensure every aspect of five:am’s production and operation processes was environmentally sustainable. In June 2010, five:am’s organic yoghurt dream came one step closer after the company secured an opportunity to provide a leading Australian supermarket with product from March 2011.

DAIRY five:am’s sophisticated and automated manufacturing facility

Product concept to reality Through working with Process Partners and using Schneider interface and by just one or two operators. The sophistication of Electric’s solutions, five:am was able to go from product con- the automation technologies installed in five:am’s plant is not cept to running a fully operational plant in just eight months. typical for plants of this size. It contains advanced technologies In March 2011, five:am’s first products were distributed and sold such as automated cleaning so it can be routinely cleaned when needed with minimal operator involvement. throughout one of Australia’s leading supermarkets. “Now five:am has one interAfter securing a contract to face for the whole plant - this supply a leading Australian superThrough working with Process Partners and using gives visualisation of everything market with its yet-to-be-produced such as batch, recipes, mixing, organic yoghurt, five:am had a Schneider Electric’s solutions, five:am was able to go pasteurising and fermenting,” tight time frame to make its prodfrom product concept to running a fully operational plant explained Francis. “The automauct concept a reality. Its success in just eight months. tion technologies from Schneider was dependent on the specialist Electric helped us achieve sustainvendors it partnered with to make able manufacturing processes by this happen - Process Partners and Schneider Electric. Schneider Electric provided a full suite of reducing wastage and ensuring a smooth running of the plant, sophisticated automation and control technology so the product enabling significant time savings from not having to manually could be manufactured as quickly and efficiently as possible. In operate and clean machines,” added Prior. “Thanks to Schneider Electric and Process Partners, we have a sophisticated, efficient March 2011, five:am’s first products were distributed. “The time taken from ordering components to delivery was just and extremely scalable manufacturing site that will allow us a matter of weeks. Schneider Electric was the only organisation to expand to keep up with customer demand. The automation that could meet this time frame,” said Francis. “The deployment technologies allow us to easily roll out new product lines and of the SCADA package was very quick as the solution could be ramp up production as we look to explore the opportunities in markets overseas,” concluded Prior. configured off-site and then downloaded at the plant.” The complete plant visualisation achieved through Schneider Electric’s SCADA package means the facility can be run from one

Jan/Feb 2012

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Schneider Electric Australia Pty Limited Contact info and more items like this at wf.net.au/M048

DAIRY

Blockformer for Irish cheddar plant Irish company Glanbia Dairy Ingredients is a leading producer of choice matured cheddar cheeses. In 2007, Glanbia decided to go for a major expansion in production capacity and an equipment upgrade with the possibility to further increase capacity as needed. The plant upgrade and capacity increase solution supplied by Tetra Pak in 2008 included a high-capacity Tetra Tebel Alfomatic - a fully enclosed cheddaring machine that can handle 10 t/h. Glanbia could meet future capacity needs by simply adding Tetra Tebel OST vats and more Tetra Tebel Blockformers. By mid 2010, the capacity need was growing and blockformer capacity had become a bottleneck. As it happens, Tetra Pak had just developed a new blockforming solution and was looking for a partner that could help out with the validation process in full-scale operation. “We had several Tetra Tebel Blockformer units already and have been happy with Tetra Pak’s supply for nearly 30 years,” said Tim Purcell, Cheese Plant Manager at Glanbia Dairy Ingredients. “The new version sounded tempting, so we agreed to validate it at our plant - and at the same time get a head start on our requirements for increased capacity.” “We are very grateful to Glanbia for their willingness to work with us in this important validation process,” says Tetra Pak’s Sales Manager Ronny Kvist. “Particularly for an extensively upgraded machine that is full of numerous new features - and provides significant benefits for the customer once all the wrinkles have been ironed out.” The Glanbia plant in Ballyragget now has a reliable cheese line producing top-of-the-line cheddar, with increased flexibilty and capacity to handle peak season volumes. “We will continue to get uniform and top-quality blocks with very little product loss,” says Tim Purcell. “We are confident that the performance criteria will be achieved.” Glanbia will soon be discovering further benefits. A new guillotine design enables fast, easy replacements with very little downtime. A fully pneumatic lowering and positioning system has nearly eliminated wear and tear. Moreover, by adding frequency converters to the vacuum pumps, energy is consumed only to the extent the pumps are needed.

SPX Over 100 YearS In The DaIrY InDuSTrY With a focus on innovation and process development, we continue to expand our product portfolio in order to provide our customers with more choices and more solutions. From engineered to customized systems, SPX helps you process dairy products your way. Contact us today to find out how our newly launched solutions and industry leading brands can help you meet your most critical processing challenges. TEL: +61 3 9589 9301, www.spx.com

Tetra Pak Marketing Pty Ltd Contact info and more items like this at wf.net.au/M216

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10 new 100 hL beer fermenters for Casella Estate Casella Estate, a company best known for the Yellowtail wine label, wanted 10 x 100 hectolitre new beer fermenters and companies from as far away as Europe tendered for the coveted project. However, an Australian stainless steel fabricator proved to be more than capable of meeting design and fabrication expectations of the food and beverage sector. ASSDA member and Accredited Fabricator A&G Engineering had a few advantages over the offshore companies: they had worked with Casella before, fabricating 88 x 1.1 million-litre wine tanks for the company’s tank farm in Yenda, NSW; they have supplied stainless steel tanks to Australia’s leading breweries, wineries and beverage companies; and they are one of the largest users of stainless steel in Australia. The five-month Casella Brewery project, completed in August 2011, saw 25 of A&G’s 200 staff use 65 tonnes of 304-grade stainless steel (including 2-4 mm coil and 8 mm plate) to build the 10 vessels. The tanks were designed to AS1210-2010 pressure vessel standards, in order to withstand a pressure rating of 115 kPa. The stainless was welded with A&G’s semiautomated welding process and the internal welds were polished to achieve a 0.6 Ra surface finish, to meet beverage industry standards of a food-grade finish. A&G built the vessels at its Griffith and Irymple plants, before transporting them to Yenda. With the beer fermenters now in place, the Casella Brewery was operational by the end of 2011. A&G Engineering’s successful completion of Casella’s project is an important victory for the Australian stainless steel fabrication industry as a whole as it proves there is no need for food and beverage manufacturers to go overseas for engineering, detailing and fabrication work. A version of this article was featured in Australian Stainless - Issue 50, Summer 2011/12. A&G Engineering Pty Ltd Contact info and more items like this at wf.net.au/M208

Close-up of Casella’s new fermenters showing stainless steel fabrication detail. Image courtesy of A&G Engineering.

Casella’s tank farm. Image courtesy of A&G Engineering.

Stretch wrapping machine TechnoWrapp has announced the release of the B300 Stretch Wrapping Machine with an automatic rotary arm and ‘Syncro’ ring guide. The machine is claimed to be the fastest rotary arm wrapping machine currently available and has an arm with a ring guide that rotates around the load at 45 rpm, wrapping 130 pallets/h with 10 wraps for each pallet. The ring is floor mounted to assist the rotary arm during rotation. The machine contains an EP-V1 electronic pre-stretch system with a tacho generator adjustable from the HMI touch screen which enables smooth dispensing of the film and a high degree of pre-stretch. The machines are designed to keep film usage to a minimum, which is achieved by pre-stretching the film by more than 400%. On a pallet measuring 800 x 1200 x 1500 mm high, using nine layers of film and a standard film reel of 500 mm wide x 23 µm, only 96 g of films is used. The Syncro device enables clamping, cutting and welding of the film while in motion, which saves time as the film is cut and sealed while it is being removed from the wrapping area. As the pallet/load is static, the stability and integrity of the stack is maintained during the high-speed wrapping process. HBM Packaging Technologies Contact info and more items like this at wf.net.au/L454 50

Jan/Feb 2012

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Bulk bag to silo transferring system A Flexicon bulk bag discharging system with integral pneumatic conveying system transfers material from bulk bags to silos and other storage vessels. Unlike most discharging systems that move material from bulk bags to smaller storage vessels and process equipment, this positive pressure pneumatic system is designed to fill bulk storage facilities on islands or other locations unable to receive large volumes of bulk material by rail or bulk truck. The discharger portion of the skid-mounted system includes a cantilevered I-beam with

BULK

electric hoist and trolley to lift and position bulk bags without the use of a forklift. A SpoutLock clamp ring forms a high-integrity seal between the clean side of the bag spout and the clean side of the equipment, while a Tele-Tube telescoping tube maintains constant downward pressure on the clamp ring and bag spout, elongating the bag as it empties to promote complete discharge. Material flow is aided by Flow-Flexer bag activators that raise and lower opposite bottom sides of the bag in timed intervals. A Bag-Vac dust collector integral to the dust-tight system creates negative pressure to collapse empty bags prior to retying and disconnection, eliminating dust emitted during manual flattening of empty bags. The unloader's surge hopper is equipped with a high-capacity rotary airlock valve to feed material into a pneumatic conveying line leading from a positive displacement blower at high rates. The company also manufactures bulk bag dischargers as stand-alone units or systems integrated with mechanical or pneumatic conveying systems, weigh batching controls, bulk bag conditioners and other equipment, as well as bulk bag fillers, bag dump stations, box/container/drum tippers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/M023

www.foodprocessing.com.au Jan/Feb 2012

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JDA helps Wrigley discover a sweet spot As an iconic confections leader for more than a century, Wrigley has experienced some significant changes, including its own acquisition by Mars, in October 2008. As one of the largest food companies in the world - with $30 billion in annual revenue - Mars provided new strength to the global Wrigley organisation. The acquisition, however, also brought a new set of responsibilities for the Wrigley category management team. “We were already expanding our business and had integrated the Lifesavers and Altoids brands into our portfolio when Wrigley was acquired by Mars,” said Mike Hettinger, Senior National Category Manager at Wrigley. “This meant integrating Mars’ Skittles and Starburst businesses into the Wrigley brand family as well since they are a natural fit with our increasing confections focus. In a short period of time, Wrigley grew from what was historically known as a world leader in gum to a confectionery company with new areas of focus.” The brand extensions, while exciting, dramatically expanded what Wrigley was doing to track and analyse its space and shelf management initiatives. Plus, the company’s field teams needed greater visibility to manage the new product diversity. “We were using an inefficient way to load the majority of our planograms that resulted in challenges to reporting out data. In addition, we were experiencing some issues that we knew our current system could not handle,” said Hettinger. “We needed a solution that would broaden our efforts on space and shelving, ensure the integrity of our data and offer the capabilities to provide greater insights.” Wrigley chose to implement JDA Space & Category Management solutions, which would enable the company to manage a large volume of retail planograms, fixtures, floor plans, store/cluster data, product attributes and performance information. “The JDA team made sure we met our aggressive timeline by working with us throughout the entire implementation process. Having them physically on-site, working through the implementation, was certainly critical to our success,” added Hettinger. “It was a seamless process with the lines blurred between Wrigley’s project team and JDA’s implementation team. As a result, the implementation happened faster than we anticipated.” According to Hettinger, one of the key factors in achieving a rapid implementation was to have JDA host the solutions. “We didn’t have to install the software, just establish an interface connection on the user PCs. Our users could log on and get right to work. JDA clearly has expertise in system administration, batch processing, data backup, remote access, security and other technical areas that we rely upon. We couldn’t have met this aggressive schedule without the managed services component,” added Hettinger. Wrigley also took advantage of JDA Education Services’ on-site training option to speed the implementation and drive a rapid return on investment.

Supply chain portal Icon Global Link and the Victorian Freight and Logistics Council (VFLC) have partnered to launch the Supply Chain Business Activity Harmonisation Study (BAHS) website: http://www.supplychainbahs. com.au/. The site will provide resources to industry and government in supply chain and logistics including training courses, reports, case studies, statistics and presentations. It will provide detail on how supply chains interact at each node and provide visibility across the entire network of both information and product flows. The portal will assist prospective and new entrants to industry to give them a feel for the complexity and challenge of working in the logistics industry. It will enable shippers/receivers a view as to how their goods actually move from A to B. It will also provide government agencies a view to see how

JDA Software Australia Pty Ltd

they interact in supply chains.

Contact info and more items like this at wf.net.au/M054

Logistics providers will also be able to see how their activities impact the flow of goods. This site will provide the com-

Food industry grippers

munity of import/export/domestic

The Schunk LMG-44 and LMG-64 stainless steel grippers can be used in applications where fresh food

freight a platform to enhance and

products are to be handled automatically, such as in processing and packing lines.

improve the industry. It is coordi-

Suitable for processing meat (pork loins, etc) and a variety of fresh food products, these polished

nating all of the past and future

stainless steel grippers can easily be fitted to robots, handling systems and other automated equipment.

work performed on Seafreight,

The pneumatically operated LMG series provides high gripping forces from a compact 2-finger angular

Airfreight and Distribution Centre

gripper and has a built-in grip force safety device which ensures the gripper does not open if air supply

Business Activity Harmonisation.

is lost. It incorporates hygienic design features such as easy-to-clean, fully sealed mechanics to IP67 and use of lubricants which are food-standard compliant.

Access is now available to online materials with SCORM-

Electrical monitoring of the gripper open/closed positions is possible via optional magnetic proximity

compliant quiz at a nominal

switches and gripping fingers can easily be custom designed to suit the product being handled. The LMG

price. Group access to whole-of-

series is maintenance free to 1.5 million cycles and can be cleaned using a washdown hose.

supply-chain awareness material

A smaller stacking gripper, SG-47, which also incorporates hygienic design features, is available for food packing applications.

Icon Global Link Pty Ltd

Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/L510 52

Jan/Feb 2012

is available at a discounted price.

www.foodprocessing.com.au

Contact info and more items like this at wf.net.au/M231

Fibre King completes end-of-line packaging for pharmaceutical company

equipment were shipped out of our Brisbane facility and we had turnkey responsibility for the installation of the four lines. Close cooperation with the client and building designer during the development phase ensured the most efficient and operator-friendly layouts. Likewise, significant upfront work with upstream and downstream suppliers minimised the chance of unexpected issues during installation and commissioning. Despite the scale of the project and the usual challenges of working in China, it was one of the smoothest installations we have delivered.” Skip Nell, Senior Packaging Systems Engineer, Pfizer Global Engineering, testifies: “Fibre King’s support in designing and installing high-quality equipment are a great asset to our business. Their equipment reliability and efficiency match their level of excellent service and support across our international network. We look forward to continuing a great working relationship in support of the current equipment in operation and upcoming projects.” Fibre King Pty Ltd Contact info and more items like this at wf.net.au/M214

www.foodprocessing.com.au Jan/Feb 2012

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Pfizer (formerly Wyeth Pharmaceticals) has invested over US$700m in capacity upgrades of its nutritional formula operations in Asia. Australian packaging machinery manufacturer Fibre King secured all the end-of-line packaging work across the three separate projects in Singapore, the Philippines and China. The latest installation at Pfizer China’s Greenfields plant established four infant formula can and carton lines, including a depalletiser, lowerator-air rinser, WAP50 dual-layer continuous motion wraparound case packers, WAP25 case packers, and CP50 and CP30R palletisers. Earle Roberts, CEO of Fibre King, said: “Pharmaceutical clients demand the highest standards of equipment, service and documentation. These requirements, teamed with the exceptionally high cost of downtime on these production lines places significant pressure on our 50-strong team. There’s no margin for error and no timeline extensions on a project like this - everything has to be perfect from the start.” In order to meet capacity requirements, Fibre King developed a new dual-layer continuous motion case packer that can run dual-layer and single-layer packs at high speeds using standard wraparound cases. “The China Greenfields installation was the largest single export installation we have done. Fourteen 12 m containers of

A review of published studies has found that handwashing with antibacterial soap produces statistically greater reductions in bacteria on the skin when compared to using non-antibacterial soap.

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Antibacterial soap more effective than non-antibacterial soap esearchers Donald Schaffner and Rebecca Montville of Rutgers University’s (New Jersey) Food Science Department conducted a quantitative analysis of existing data in order to determine if there was a difference in effectiveness between antibacterial and non-antibacterial soaps. “A difference in the effectiveness of antimicrobial and non-antimicrobial soaps appears to exist and is repeatedly observed through a variety of analyses; antimicrobial soap is consistently and statistically always more effective than non-antimicrobial soap,” the researchers wrote. The research article - A Meta-Analysis of the Published Literature on the Effectiveness of Antimicrobial Soap - reviewed a total of 25 publications containing 374 observations found to have examined use of both antibacterial and non-antibacterial soap in the same study. “Although differences in efficacy between antimicrobial and non-antimicrobial soap may be relatively small, they do exist, and small but significant differences in pathogen levels on hands can have a significant effect on public health,” wrote Schaffner and Montville. Added Dr Schaffner: “In addition to our findings on antimicrobial effectiveness, I was really struck by the similar behaviour of very different species of bacteria in response to antibacterial soap. In other words, we found that antibacterial soap did its job against a variety of bacteria, including E. coli and Staph.” The research was published in the peer-reviewed Journal of Food Protection (Vol. 74, No. 11 2011, Pages 1875-1882). It was supported by the Topical Antimicrobial Coalition, which consists of the American Cleaning Institute and the Personal Care Products Council. 54

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