What’s New in Food Technology July/August 2012 by Westwick-Farrow Media

CEOS KNOW GLASS IS A GREAT DINNER GUEST. “S. Pellegrino® is the perfect companion to fine foods,” says Stefano Agostini, Chairman and CEO of Sanpellegrino S.p.A. “And glass is a perfect packaging for our brand. Our mineral water is sophisticated, the bottle is elegant—together, we add sparkle to the meal.” GlassIsLife.com makers of charming, tasteful, food-loving glass packaging

bulk handling, storage & logistics

Managing food safety

packaging

26 Measuring the migration of ink in packaging

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©iStockphoto.com/Angelika Schwarz

10 The future of freezing is served on a plate

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©iStockphoto.com/ Vladimir Vladimirov

food for thought

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contents

July/August 2012

32 35 64 68 ingredients and developments 32

No-fat, low-fat dressings don’t get most nutrients out of salads

processing

37 Third-party audits and food safety, Part I 46 Robotic system automates poultry deboning process

bakery, cereals and grain

testing and quality assurance

64 Grains of truth about staple foods

72 Come and see the latest in food processing and packaging

57 Beginner’s guide to cleaning in place 61 Juice packaging using wastewater sugar

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July/August 2012

©iStockphoto.com/Johannes Norpoth

Keeping the mice down Did you know that whole wheat which has been partly eaten by mice has a kibbled appearance; whereas, if it had been partially eaten by a rat, it would have a chopped appearance? I have to admit that it has never crossed my mind to investigate this before and I’ve never had a rat and mouse on hand to run trials. But, you have to admire rodents for being some of the most successful mammals on earth. Their reproductive potential, natural cunning and survivability, combined with their ability to adapt themselves to almost any environment, are pretty remarkable. I suppose they would gain much more respect if they didn’t also have the capability to spread many human pathogens such as Salmonella spp, Listeria spp, Escherichia coli, Cryptosporidium parvum, Leptospira spp, hantaviruses, bubonic plague and toxoplasmosis. We would also probably like them more if they didn’t have the potential to dramatically affect our brands and our profitability. It’s kind of odd, the things that can affect the food industry. We have so little room for error. In most other industries there is a higher tolerance for mistakes, but in the food industry, even small oversights can have fatal consequences. Contrary to the mining industry we cannot ‘absorb’ a few rats in our ranks. Which brings me to the point - how to keep the rats and other workplace pests and risks at bay. And the answer is education (and then putting into place and maintaining what you have learnt). Luckily we are now right into ‘conference season’. That time of the year when you and your peers all attend a myriad of symposia, seminars, exhibitions and conventions. You put your best smile on and go forth to reacquaint yourself with some colleagues, meet new people and gather the latest information relevant, and maybe not, to your business. I am always amazed at what I learn at all of these events. Often the bits I assume will be boring time-fillers are riveting and the bits I have been looking forward to don’t live up to my expectations. Almost always the highlights come in idle conversation with other event attendees. The AIP and AIFST conferences are over now but there are others still well worth registering for. You can read about the Australian HACCP conference and NZ’s Foodtech Packtech in this issue. If you, your company or your association is holding a food industry relevant event, I would love to hear about it. Our website, www.foodprocessing.com.au, has an events page where your events can be posted or you can visit it to discover events you would like to attend. No need to be shy - we are all out there trying to keep the rats at bay!

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

July/August 2012

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Are your non-food products, equipment and materials FOOD SAFE?

Are your service suppliers FOOD SAFE and HACCP compliant?

Be sure, be FOOD SAFE Look for the food safety mark

www.haccp.com.au Looking for food safe products or services? Call us on 02 9956 6911 or visit the ‘Endorsed Suppliers’ page on our website.

HACCP AUSTRALIA

FOOD SAFE PrODuctS AnD SErvicES

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As part of 2012 Food Allergy Awareness Week, GS1 Australia has announced an iPhone app that gives consumers access to extended labelling product data. The GS1 GoScan was launched yesterday and will be available from September. By scanning a product’s barcode, consumers can receive comprehensive product data, including allergen information, ingredient lists, nutritional content, Daily Intake information and dietary information such as Kosher, Halal, vegan, organic. The app also supplies preparation, usage and storage instructions, country of origin, product descriptions and images. GS1 Australia CEO Maria Palazzolo said food manufacturers have been diligent in updating food labels to provide consumers with greater information, but the next step to secure food safety needs to be taken.

FOR

image©iStockphoto.com

iPhone app for food allergy sufferers launched “We implore companies - from brand owners and manufacturers right through to retailers and wholesalers - to get on board the latest initiative to drive better availability of trusted product information for consumers,” said Palazzolo. GS1 Australia says it has collaborated with Anaphylaxis Australia to ensure GS1 GoScan meets allergy sufferers’ needs. Anaphylaxis Australia, along with major retailers, international food companies, the Australian Food and Grocery Council (AFGC), Australian universities and other national health organisations, worked in partnership with GS1 Australia to research and develop the app. “This week is an important vehicle for us to tell allergy sufferers, their friends and families about the new tool that will help them manage their food requirements, by accessing trusted product information via their iPhone at the supermarket,” Palazzolo said. “At the same time, brand owners can be sure that consumers are accessing up-todate and accurate information about their products - thereby building brand trust and loyalty.”

thought GS1 NZ announces online service for rapid recall or withdrawal of products GS1 New Zealand is urging companies in the food and grocery sector to register for ProductRecallnz, an online service for rapid recall or withdrawal of products in consumer supply chains. ProductRecallnz enables companies to send and receive standardised recall or withdrawal notices with greater efficiency than current ad hoc practices. The service helps manufacturers, suppliers, retailers and others manage consumer safety and other business-related risks when a recall or withdrawal becomes necessary. Regulatory advice for the service was provided by the Ministry for Primary Industries - the regulatory body that oversees food product recalls and withdrawals in New Zealand. Companies must be registered in order to use ProductRecallnz and must be full members of GS1 NZ. The service was announced several weeks ago and, since then, 16 major suppliers have already registered. Companies that register prior to the official 23 July launch will have immediate access to the service;

July/August 2012

those registering after 23 July will have an eight-week standdown period. “The more companies that register and the sooner they do, the more efficient and effective ProductRecallnz will become across the food and grocery sector,” said Dr Peter Stevens, Chief Executive of GS1 New Zealand. “It is an easy-to-use online tool that companies should have at their fingertips, in full recognition that it might be needed any time and that the benefits are potentially huge in terms of protection for consumer safety, for revenues, for business reputation and so on.” GS1 NZ developed ProductRecallnz in collaboration with the Foodstuffs Group, Progressive Enterprises, the New Zealand Food & Grocery Council, Cadbury, DB Breweries, Fonterra Brands, Goodman Fielder, Kimberly-Clark and Nestlé. The organisations are now calling for sector-wide registration. To r e g i s t e r f o r P r o d u c t R e c a l l n z , v i s i t www.productrecallnz.co.nz. For more information, call 0800 10 23 56.

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Nanotechnology could benefit vegetable industry Developments in nanotechnology could help production of the humble vegetable. Speaking at the AUSVEG Future Technologies Seminar in Hobart on 9 May, Dr Terry Turney from Monash University explained how products that were previously only science fiction imaginings are becoming a commercial reality. “According to Dr Turney, food packaging could be advanced to such a stage where it could determine whether the produce it contained was suitable for human consumption,” said Richard Mulcahy, CEO of AUSVEG. “Among Dr Turney’s forecasts was the ability for personal printers to produce objects as sophisticated as flexible batteries as a result of nanotechnology.”

Dr Turney, who is the Chief Technology Officer of Sonic Essentials, also discussed the issue of food scarcity and argued that nutrient quality must be addressed as many food sources are lacking in essential nutrients. AUSVEG - the national peak body representing vegetable growers conducted the seminar to help further industry knowledge and explore the future application of technologies to the industry. “The Australian vegetable industry is one of the most progressive in the world, and it is vital that we continue to move forward and think about future practices, innovations and technologies,” said Mulcahy.

2012 APPMA Scholarship winner announced The winner of the 2012 Australian Packaging & Processing Machinery Association (APPMA) scholarship has been announced. Mark Dingley, APPMA Chairperson, announced at the 2012 Australian Institute of Packaging (AIP) National Conference last week that Anna Roland is this year’s scholarship winner. Roland is a Technical Officer with Betta Foods Australia. The APPMA scholarship will enable her to undertake a Diploma in Packaging Technology through the AIP. “Anna has had the opportunity to work within the food and packaging industries and has completed various projects including assisting in film sealing, which was her first exposure to the complexities involved in designing and implementing successful packaging,” Dingley said. “During the judging it was obvious that she has made a sustained effort and commitment to her studies to date and has gained the support and confidence of her employer and recognition of her professional aspirations.” Roland said the scholarship gives her the opportunity to develop her understanding of the design and practical aspects of packaging. Without the scholarship, she said, it would take her much longer to save up to complete the qualification. “I am hoping that the learnings from the Diploma in Packaging Technology will provide greater support to the production floor and in the development of new products by our marketing and technical teams,” Roland said. “In a few years I hope that I will continue to be learning and challenged every day to use all the skills I have developed, and hopefully see the fruits of my current role in improving GMP, process improvement and implementing new products.” Roland will commence the diploma this year.

Coles to use Australian vegies for its frozen vegetable lines Coles has announced that all of its Coles-branded frozen vegetables will now be sourced from Australian vegetable growers. The supermarket giant announced the move in conjunction with vegetable processor Simplot and the Tasmanian government. AUSVEG, the peak industry body for Australian vegetable and potato growers has endorsed the decision. “It’s encouraging to see that processors are working with government and the retail sector to ensure the future of the Tasmanian vegetable industry,” said William Churchill, AUSVEG Public Affairs Manager.

“Consumer studies have shown that 80% of people want to purchase Australian produce and support their local farmers. Today’s announcement is an excellent step towards giving the consumer the choice to make those decisions.” In 2011, Australia imported $651 million worth of produce, $231 million of which was frozen vegetables. Coles’ decision to use Australian vegetables for its frozen line will ensure that about $40 million of frozen vegetable sales will support local vegetable farmers, AUSVEG said.

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July/August 2012

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Managing food safety

Changes to the way governments and businesses operate have particular significance for food businesses and their management of food safety. To help you to navigate the food safety path, the 19th Australian HACCP Conference will deliver the expertise of 20 leading professionals and exponents of food safety from Australia, New Zealand and the USA. Conference attendees will learn about important legal and technical updates, new technology applications, risk implications from corporate change plus take a glimpse into the future for the Australian food industry. What: 19th Australian HACCP Conference When: 3-5 September 2012 Where: Rosehill Gardens, Sydney, NSW, Australia Registration and more information: www.haccptown.com.au/Australia/html/conference.htm

he Australian HACCP Conference is the premier discussion forum for all Australian food industry professionals involved in food safety. Each year the conference attracts a loyal following together with a growing number of delegates involved in the development, implementation and maintenance of food safety programs. It is the largest dedicated food safety conference in the Asia-Pacific.

Conference topics Brand protection through food safety This conversation session will discuss issues that food safety presents for corporate branding, in particular: why food safety is so important to consumer perceptions and brand image, the implications of safety breaches and how food safety is managed across the organisation. Career paths in food safety management What are the key elements of a successful career in food safety management? This session will examine the pathway to professional status in the food safety arena. Corporate management versus risk management Significant changes within the food industry have occurred over the past 10 years relating to organisational structures, responsibility and, as takeovers have occurred, the globalisation of the food trade. Learn from two industry professionals about moving from local to global food safety management and managing a food business through corporate change. Food production chain Q&As At seemingly polar ends of the food chain conversation are the complex areas of preservatives and organics. As the messages about health and food increase, this session seeks to look objectively at both sides of the coin for each of these topics. Foodborne outbreaks in produce - lessons learnt During the past 18 months there have been two unprecedented foodborne outbreaks in the produce industry - one in sprouts in Europe and one in melons in the USA. Both led to a large 8

July/August 2012

number of deaths and have gone down in history as the worst foodborne outbreaks in those regions. This two-part session will examine the contributing causes to outbreaks and how the risks can be reduced to prevent outbreaks in the future. Issues and advances in food control technology All food manufacturing and food service businesses face changes in technology and in thinking how to manage GMPs on a daily basis. These case studies will explore advances in technology to manage issues such as breakdown in production floor surfaces and advances in cleaning technology. Legislation and technical updates Processes have been recently put into place to allow for changes to the Australian and New Zealand labelling laws under the Food Standards Code as well as in the way the food import inspection program is managed. Further to this, there has been ongoing research into food allergens leading to changes in threshold values as per the VITAL tool. These sessions will provide updates on these areas. The future of the Australian food industry What does the future hold for all the key players in the Australian food industry? Here we will examine the issues of food supply and the global food supply chain.

Associated master classes Product recall planning In this hands-on workshop you will get to explore many of the practical issues that companies face in a product recall situation. Understanding the full food safety audit process Learn about all the key elements of a food safety audit, how they connect and what plans your organisation can implement to ensure audit success. Visit the conference website to register to attend and to see the entire program. Advancing Food Safety Pty Ltd Contact info and more items like this at wf.net.au/Q665

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The future of freezing is served on a plate

Sean McGowan

One of Australia’s leading packaged meat exporters recently upgraded its refrigeration plant to include automated plate freezing technology. In doing so, it increased capacity by over 20% while reducing labour costs.

late freezing has been used in the meat, fresh produce and dairy industries for many decades, offering a range of benefits over alternative forms of freezing such as air blasting. The process sees refrigerated, aluminium plates compress to make direct contact with a product placed in between. Heat is transferred by conduction from the product, via packaging if any, to the evaporator surfaces (the plates) containing a refrigerant, often ammonia. The freezing cycle, in the case of packaged beef, is 24 hours compared to 48 hours for air blast freezing. This is just one of a number of benefits that outweigh the cost impost associated with the technology, which is typically 40% greater per unit quantity frozen. Others include improved shipping efficiencies resulting from the use of uniform-sized cartons that are both flat-topped and bottomed to allow for sufficient contact with the plate surfaces; and a reduction in energy costs associated with the elimination of fans. According to Brendan Dever, Business Development Manager with Milmeq, plate freezing is widely used to freeze beef, lamb, offal, pet food, fish and cream in Australia, New Zealand and around the world. He says that along with supplying the world’s largest horizontal plate freezers, the company also supplies vertical plate freezers commonly used on fishing trawlers for rapid freezing of seafood while at sea.

Inside plate freezing Many Australian packaged beef manufacturers use plate freezing, particularly if geared for the export market. The process typically involves cartons of beef travelling to the plate freezer enclosure on a conveyer belt directly from the boning room, where they are ‘marshalled’ into ‘slugs’ on the in-feed conveyer of the nominated plate freezer and pushed onto the plate station via an electricoperated pusher. 10

July/August 2012

When the station is loaded, the stack indexes upwards for loading of the next station, with the transfer of the carton slugs onto the plate ejecting the same number of frozen cartons onto the unload conveyer at the rear of the stack. When all stations are loaded, the stack lowers until it is closed and a hydraulic closing pressure is applied to ensure full plate contact on the top and bottom surfaces of the carton. Here, the typical evaporating temperature is -40°C. According to Dever, dehumidification is among the most important elements in providing optimum availability of the plate freezers. He says that typically, a stream of low dew point air is directed into the plate freezer enclosure to maintain a positive pressure and a dew point of between -30 and -35°C. “A dry enclosure ensures that photo sensors used in the freezing process remain frost free,” says Dever. “It also means the time between defrosts can be extended from months to almost indefinitely.” Plate freezing technology has made large advances over time, with manually operated, semiautomatic and fully automatic systems offering varying degrees of control. Manual plate freezers allow for loading and unloading of product by hand, with the plate stack hydraulically lifted, presenting the station at the optimum height for the operator. Spacers can either be fixed or removable, the latter providing the advantage of allowing the stack to be collapsed to a lower height when unloading, thus reducing building height requirements. Semiautomatic plate freezers allow the operator to manually set the stack to the load height, with the ‘carton slug’ marshalled onto the load conveyer at the front of the plate freezer. The operator initiates the electric pusher through a push and return cycle, and a row of fresh cartons is transferred to the plate, displacing a row of frozen cartons at the rear.

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Fully automatic units provide for cartons to be loaded and unloaded automatically, with a PLC controlling the conveyers, hydraulic lift cylinders, carton loader and carton gates. Operator control is via a HMI screen. When the operator initiates auto operation at the commencement of a shift, the system opens the current plate freezer to the last station and row loaded on the previous shift and commences loading at that row. The PLC controls loading of individual stations, sequencing through the stations in each plate stack and preparing subsequent stacks to be loaded. In the event of an interruption to loading, perhaps as a result of misshapen cartons or loose carton flaps, the operator is instantly alerted.

The Throsby experience EC Throsby Pty Ltd is one of Australia’s leading packaged beef exporters, with the family having grown and processed livestock in the New South Wales Hunter Valley since the early 1950s. Its current hot boning process plant in Singleton produces product lines such as bone-in and boneless beef, offal, fancy meats, tripe and other beef products, of which about 98% is exported. Built in 2000, the state-of-the-art facility features a slaughter floor, boning room, offal and tripe rooms, cold store, rendering plant and plate freezers - all designed and constructed to deliver high productivity with a minimal impact on plant operators or the environment. The majority of the equipment in the plant was originally supplied by Milmeq, so understandably, the company was approached by EC Throsby and consultant Meateng in 2010 when a facility upgrade was planned. The upgrade intended to add a fifth plate freezer beside the plant’s existing four manual units to improve plant capacity and allow for a planned increase in production. This option was rejected, however, due to plant disruption

and time constraints. It was then that the construction of a stand-alone building to house the additional plate stack was proposed. During discussions, Milmeq drew on its 40-plus years of experience in refrigeration and freezing systems and proposed that the existing four manual plate freezers be relocated to the new building with the addition of four stations to each stack, and that they be converted to fully automatic operation. With this configuration, EC Throsby also intended installing a comprehensive conveyer sorting and palletising concept to remove labour intervention from the boning room through to freezer, sorting and palletising. This would provide the increased capacity required, while also improving efficiency and allowing the redeployment of labour to other parts of the plant. Being a mining area, businesses in Singleton are subject to continuing pressures in sourcing personnel. “When the decision was taken to extend and automate the existing manual freezers, relocation was the only option that would allow the project to be completed within the annual plant shutdown period,” says Dever. The new building was constructed by EC Throsby in the latter part of 2010, and part of the plate freezer infrastructure, including access platforms and walkways, was in place prior to the shutdown of the manual plates. Additional work was also required to extend the structural frame of the facility and fit new lift cylinders. With the manual plate freezers handed over to Milmeq on 27 December 2010 and the new facility set to recommence operations just 20 days later, the timeframe naturally proved challenging to all involved. “It was overcome through detailed planning and the close cooperation of the parties involved,” says Dever. “In particular, the efforts of Peter Thompson and the team at Meateng were critical in coordinating the project www.foodprocessing.com.au

July/August 2012

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activities. The building construction program, the production requirements of the client and the plate freezer program were project managed by Peter Sullivan and EC Throsby.” By adding four new plates to each of the original four plate freezers, capacity was increased by 22%. Their conversion to automatic operation also offered a secondary advantage and a possibly greater impact, says Dever, by improving the entire production flow through the plant. “Under the manual operation, a team of workers would fully unload two plate freezers, before part of that team would begin palletising and loading those cartons to containers or freezer storage. The rest of the team would load new production into the emptied plates,” he says. “This process would then be repeated for the remaining plates. Apart from the inherent disadvantages of working in batch lots, it also reduced the closed freezing time for the plates to 16 hours per cycle.” The change to automated load and unload immediately removed these inefficiencies and resulted in a very steady flow of product from the packing areas to containers and freezer storage. “It also allowed an increase in freezing time to 20 hours, with an accompanying rise in plant room evaporating temperature, resulting in a very significant annual energy saving,” Dever says. Over 12 months since the upgrade plant was commissioned, it continues to operate as intended with the design increase in plant room evaporating temperature now implemented. Along with forecast labour savings being realised, it has also resulted in vastly improved carton presentation, almost eliminated damage claims and reduced forklift movements with a subsequent reduction in structural repairs and maintenance. Dever says the ongoing maintenance requirements of the plate freezers will be negligible, with service checks carried out quarterly and only the dehumidifier requiring regular filter cleaning. The desiccant rotor requires replacement at approximately seven-year intervals, while the hydraulic lift cylinder - typically a 200 mm bore cylinder with 5 m stroke - requires seals to be replaced at five- or ten-year intervals depending on duty. The only other maintenance requirement of the plant is that of the conveying systems, which are similar to chilling and freezing tunnels with an equivalent throughput.

An emerging one is the freezing of meat for human consumption, via direct contact between vertical plates - a process that has apparently been used for many years in pet food processing. However, a hurdle confronting this application is local regulations relating to the contact of food with aluminium plates. While permissible in Europe, this is not the case in Australia, where plates must feature an inert coating such as teflon. “In existing operations in Europe, the meat is frozen in 80 mm blocks between vertical plates, then automatically unloaded and stacked on pallets with a thin film separating each block on the pallet,” explains Dever. “The entire pallet load is then protected with an outer shrink-wrapped layer.” He says the advantages of this process relate to the elimination of packaging. Freezing times are faster, packaging and disposal costs are reduced, and the incidence of product contamination from plastic being trapped during the freezing of conventional cartoned product is lessened. “Even though the Australian meat industry has generally adopted a carton size based on CSIRO’s work in the 1980s to promote a standard carton for manufacturing meat, the reality is the slight dimension variations between plants mean that each plate freezer needs to be custom designed and built,” says Dever. This means varying carton sizes can also be accommodated for, as was the case at the EC Throsby installation where the plate freezer design allowed for up to three different carton sizes. “Typical plate freezers in the seafood industry are designed for a product thickness of 70 to 80 mm, with freezing times of a few hours. Conversely, the export beef industry is geared to the 27.2 kg carton that is typically 160 mm thick,” adds Dever. “As such, all conditions need to be optimised to achieve the required core temperature within a 24-hour cycle.” As the supply cold chain continues to improve, and international demand for Australian produce increases, plate freezing technology is sure to play an important and evolving role in local manufacturing. This article originally appeared in the the AIRAH publication HVAC&R Nation. It is reproduced with permission.

Future freeze Dever says plate freezing technology continues to evolve, as does its range of applications. 12

July/August 2012

Milmeq Pty Ltd Contact info and more items like this at wf.net.au/Q375

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Ocme palletisers improve logistics for Italian wine cooperative

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Packaging equipment company Ocme recently installed a centralised palletising plant and packing lines for wine cooperative Cavit S.C. in the Trentino region of northern Italy. Formed in 1950, Cavit is a cooperative that represents 4500 of the region’s wine growers who are members of 11 cellars. Cavit’s headquarters handle 60% of the wine production in the Trentino region. Ocme has a long relationship with Cavit, having supplied the cooperative’s packaging machinery since 1976. Cavit currently has four filling lines, operating at 180 cartons per minute. The cooperative was seeking a single solution for the four production lines for product storage, palletising and wrapping with stretch film for the total output. After labelling and verification of the weight and shape, the products needed to be transported to their new automated warehouse via two automatic elevators with a drop of 5 m. Other companies’ solution proposals involved four palletisers; Ocme came up with a solution requiring only two, reducing the number of operators and amount of annual maintenance required. Ocme installed a centralised solution of two automatic palletisers to handle production from the four filling lines. The systems can palletise two different products at the same time on two pallet sizes. Each palletiser uses a new rotating system for the separation, division and preparation of the packing layer through manipulators. The system has increased efficiency as it gently handles the packs, reducing damage to cartons. The new system centralises all production data, statistics and diagnostics on PC, enabling users to create new palletising programs. Ocme has installed similar palletiser units for a range of food and beverage companies, including Barilla, Plasmon, De Cecco, Buton and United Distillers (now known as Diageo). HBM Packaging Technologies Contact info and more items like this at wf.net.au/Q148

Connectivity product range Designed to replace expensive,

IBC-based powder packer

time-consuming hardwiring meth-

Mixing and packing the same recipe over and over is easy,

ods, Turck’s line of power-

even when producing at high capacity and automation

fast connectivity products are

level. Today, recipes are constantly changing, creating a

claimed to provide a robust and

bigger challenge, especially when the appropriate cleaning

reliable modular wiring solution.

required between recipes is taken

The powerfast line is a full

into account.

series of cordsets, receptacles,

Matcon’s IBC-based Powder Pack-

reducers, reducer tees, field wireables,

er provides fast and accurate packing

rotary disconnect switches and power lock

into 10-25 kg bags. According to Matcon, cleaning the powder packer takes minutes, rather than hours.

devices that allows users to configure a custom power distribution system. The connectivity components are UL approved and available

The packer has been upgraded,

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form for improved accuracy and a

ing easy installation and customisation, the powerfast system

higher IP rating for arduous appli-

delivers flexible design capabilities, quick modifications and

cations. The sack clamp arrange-

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ment has been changed to allow

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easy cleaning access. Optional

lights, heaters and other electrical devices. They are suitable for

‘self-learning’ software is available

use in applications such as conveying, machine builders, food

to improve control of variable flow

and beverage, automation system designers and integrators,

patterns from a single recipe.

sorting machines, packaging and palletising, automotive and solar.

Matcon Pacific Pty Ltd

Turck Australia Pty Ltd

Contact info and more items like this at wf.net.au/N889

Contact info and more items like this at wf.net.au/Q329

July/August 2012

www.foodprocessing.com.au

BULK

Supermarket giant floored Ongoing maintenance issues with flooring led supermarket group Coles to commission a rigorous trial of polyurethane concrete-based resin flooring to find a finish that could withstand the demands of busy food preparation areas. Finding that their epoxy floor finishes in the deli, bakery and chicken preparation areas constantly needed repairs and maintenance, the supermarket group commissioned the six-month trial, examining a range of floors for quality, durability, wear and overall safety. Coles selected Sika’s Sikafloor-22N PurCem finish based on its suitability for food preparation areas, including slip resistance, heat resistance and resistance to food acids and fats - especially chicken fat. Coles found it to be flexible, quick-drying and easy to maintain and clean. Sikafloor-22N PurCem is a water-based polyurethane screed with a 4 to 9 mm thickness suitable for wet or dry processing environments including bakeries, meat and dairy preparation, commercial kitchens and catering facilities. The fast-curing product, which can be applied to green concrete, offers high wear and thermal shock resistance and is certified for food industry use. Coles needed to consider downtime when selecting a flooring system. Sikafloor PurCem’s speed of placement, mostly with a single step application, enables completion within tight time frames and even in live trading situations, making it a suitable choice for Coles’ needs. Installed with integrated coving for a seamless finish, the Sikafloor PurCem is expected to withstand constant traffic, impact from utensils, hot water washdown, cleaning chemicals and food acids. It also has a neutral odour and low VOC emissions. “Surfaces within all food-related businesses, from manufacturing to service, must be durable to withstand the constant demands placed on them - and flooring is one of the most vital components,” said Anthony Lewis, Project Manager, Sika Australia. “A pressing problem in the industry is the breakdown of floors due to food acid attack, resulting in constant and costly repair and resurfacing works to fix damaged floors. The Sikafloor system is a solution to long-term floor maintenance, while also upholding hygiene, health and safety standards.” Having passed the rigorous six-month Coles trial, the supermarket group has installed the Sikafloor-22N PurCem system in 30 Coles supermarkets as part of a national specification, with additional stores to be refurbished in coming months. Sika Australia Pty Ltd Contact info and more items like this at wf.net.au/Q244

Mobile half-frame bulk bag discharger Flexicon’s mobile half-frame bulk bag unloader with multipurpose hopper allows material to be discharged from bulk bags, manually tipped from sacks and conveyed to downstream processes and storage vessels dust-free. The bulk-bag-to-hopper interface has a Spout-Lock clamp ring positioned atop a pneumatically actuated Tele-Tube telescoping tube, allowing dust-tight connections and unrestricted flow between the bag spout and hopper, as well as automatic tensioning of the bag as it empties to promote flow and evacuation. The telescoping tube raises the clamp ring assembly that seals the clean side of the bag spout to the clean side of the telescoping tube and then lowers until the bag spout is pulled taut. Once the spout is untied, the telescoping assembly exerts continual downward tension on the spout, elongating the bag as it empties. The seal between bag spout and clamp ring allows full-open discharge from bag spouts of varying diameters. An integral Bag-Vac dust collector creates negative pressure within the system to collapse empty bags prior to retying and disconnection, eliminating dust emitted during manual flattening of empty bags. Flow-Flexer bag activators raise and lower opposite bottom edges of the bag at timed intervals, loosening compacted materials and promoting material flow into the bag discharge spout. The integral flexible screw conveyor transports both free-flowing and non-free-flowing bulk materials, including products that pack, cake, smear, seize or fluidise. The conveyor support mast cantilevers from the frame and runs parallel to the conveyor tube, allowing the castor-mounted system to manoeuvre in restricted areas. Units are available in carbon steel with durable industrial coating or stainless steel to industrial, food, dairy or pharmaceutical standards. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/N902 16

July/August 2012

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Cyclone screener

Load cell system

The Type DA 650 Vario cyclone

Available to rent, the Futek IHH500 load cel force gauge system

screener removes the need for an

operates at up to 20 t in compression and tension. The display

additional upstream dosing unit,

for these load cell systems is a handheld microcontroller that

due to the built-in, self-dosing

can be mains powered where appropriate, but offers up to

device. The dosing capacity can

30 hours of battery life. Including a 21 k-point data logger, the system has a simple

requirements by means of the

tare function and can display ‘max hold’ using a single front

frequency converter.

panel key. Both a 2 t range and a 20 t range are available.

BULK

be adapted to specific process

The bulk material enters the

The TEDS automatic load cell detection can process up

dosing screw via the product

to 48,000 Sa/s. It has a large, clear, backlit LCD and a USB

inlet and is transferred into the

interface. According to the company, the system offers good accuracy of ±0.001%.

screener housing. The dosing rate

TechRentals

of the bulk material required for

Contact info and more items like this at wf.net.au/Q116

the screening operation can be set to product-specific values by adjusting a frequency converter for the screw speed. The bulk material is picked up by the separately driven intake distributors with agitator bars and gently swirled through the screen basket. The fines drop through the screen basket into the fines outlet while the coarse material is transferred to the coarse material outlet where it is discharged. For inspection purposes, the screen basket can be easily pulled out and swivelled to the side of the housing by means of a special extraction device with quick-release fasteners. This enables detailed inspection and fast replacement of the screen if necessary. The dosing screw can also be pulled out and swivelled to the side. All connections relevant to safety are protected by electrical safety devices which immediately shut down the machine when it is opened. The screen fabric, which is mounted on rings, can vibrate and therefore clean itself automatically. The built-in baffle ensures that too much fine material cannot enter the coarse product outlet. The screener is retrofittable at any time and is completely extractable without the need for tools. Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/Q425 www.foodprocessing.com.au

July/August 2012

BULK

Swarf-resistant energy chains igus claims its RX plastic energy tube is almost 100% airtight, with the result of 2.7 g chips after 251,900 cycles during testing. The company has also carried out underwater tests to comply with the absolute airtight requirement, IP40, TÜV Saarland. The rounded design without undercut or edges and the smoothly curved outer contour allows chips - from coarse to tiny particles - to slide off. In addition, the connection elements and fittings are concealed, so that chips cannot be caught on these either. The energy tube is easy to open and can quickly be swung open in the outer radius. Three design sizes with an inner height of 52, 62 or 73 mm are available, as well as a design size available with a maximum inner height of 42 mm. The 42 mm size is available with the option of a high-temperature variant, resistant to hot chips up to 850°C and also as a variant with reverse bending radius (RBR). The company claims the energy chain is resistant to dust, dirt, oil, aggressive environment conditions, humidity and heat. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/N904

Bag flattener Bag flatteners are designed to shape filled and sealed bags to provide a shape most suited to packing. Bags that are out of shape due to the filling process can be difficult to pack into cardboard boxes and can impact correct sealing of cartons. Enmin Vibratory Equipment’s Bag Flattener accommodates bags up to 250 mm in width. The Enmin Bag Flattener involves two basic components. One is the Vibratory Compaction Conveyor that subjects the filled bag to controlled vibration and in the process fluidises the material, causing it to flow into all the sections of the bag. As the bag is being transported forward the second component comes into play: the Overhead Platen Conveyor, which can quickly be adjusted to increase or decrease the pressure being applied to the bag as it is vibrated and conveyed forward. The action of both the Vibratory Compaction Conveyor and the Overhead Platen Conveyor produces a gentle ‘squeegee’ action as the bag is flattened and conditioned. Since the vibration conveyor and the platen conveyor can be adjusted in terms of vibration, speed and squeegee pressure, a variety of bag dimensions up to 250 mm wide can be accommodated and adjusted for a variety of materials. The Enmin Bag Flattener is constructed in stainless steel and has been designed to be adjusted without the use of tools. Safety issues relative to the food industry have been addressed, the company claims, as well as noise considerations. The overall compact design will suit existing or new belt conveyors and can be supplied as a bolt-down or mobile facility. Enmin Pty Ltd Contact info and more items like this at wf.net.au/N899

Comprehensive Range including steel, stainless steel & plastic hybrids • Strength & Versatility • Custom configured to your application • Local Manufacturing (Aust & NZ)

For direct connection to your closest branch

1800 635 947 (in Australia) 0800 285 837 (in New Zealand)

www.locker.com.au www.lockernz.co.nz Leading manufacturer and supplier of metal belting 18

July/August 2012

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180x67mm

Antibacterial steel for cool room panels Colorbond Permagard steel combines strong Colorbond steel with Microban antibacterial technology to inhibit the growth of bacteria such as Escherichia coli. Permagard steel is suitable for cool room panel construction. Colorbond Permagard steel is either approved by, or in compliance with, the regulatee for Food, the United States Environmental Protection Agency, the United States Food and Drug Administration and the Australian and New Zealand Food Authorities. The steel is certified by HACCP Australia as a FoodSafe product for ceiling and wall linings of food storage and processing facilities. Colorbond says the steel works continuously and will not wash off, making it suitable for areas that are difficult to clean. The company claims the steel remained effective and resistant to corrosion after tests involving simulated cleaning using typical cold room detergents over a period of 10 years. The product can be used in a range of applications such as cool rooms and facilities that store and process food items where food hygiene and safety is a primary concern, including supermarket cold storage areas, food processing plants, abattoirs and wineries. The product is available in a range of panel thicknesses from 50 to 200 mm.

BULK

tions of the European Union Scientific Commit-

Multipurpose filler for dispensing bulk solid materials Flexicon’s Multi-Purpose Filler dispenses bulk solid materials into boxes, drums and bulk bags by weight. Its fill head seals dusttight against the inlet spout of bulk bags or connects to transition adapters that seal against open boxes or drums. It is mounted on load cells tied into a PLC that controls upstream devices to fill containers at high- and then trickle-feed rates to maximise the number of containers filled per hour while maintaining accuracy. An automated vibratory system raises and vibrates the container deck to deaerate and densify material. The filler’s low-profile configuration also allows filled containers to be removed with a pallet jack. A manual fill-head height adjustment accommodates all popular bag sizes, while pneumatically retractable bag hooks, an inflatable connector to seal the bag inlet spout and a feed chute outlet port allow dust-free air displacement during filling. Quick-action clamps connect the transition hood to a fill head to fill boxes from 915 to 1220 mm on a side and 990 to 1117 mm overall height. For 114 to 208 L drums, a pneumatically actuated telescoping drum-filling adapter swivels inward for connection to the fill head using quick-action clamps, after which an inlet plate is sealed against the rim of the drum. Manual push-button or electrical contact closure initiate filling cycles, after which filling, deaeration and any disconnection of the equipment from the container inlet are automatic. The filler is constructed of carbon steel or stainless steel finished to industrial, food, dairy or pharmaceutical standards, and is offered with a mechanical or pneumatic conveyor deliv-

Stellar Concepts

ery system integrated with the user’s upstream process equipment or other material source.

Contact info and more items like this at wf.net.au/N975

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/Q291

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July/August 2012

Packaging NEWS

AIP recognises packaging technologists at 2012 National Conference At the 2012 National Conference the Australian Institute of Packaging (AIP) recognised four packaging technologists for significant contribution to their specific packaging field and to the wider packaging industry, including the seventh only Founders Award in 50 years. AIP Founders Awards The Founders Award has only been awarded six times in the last 50 years and is only presented to those who give outstanding performances which in a real way enhance the profession of packaging technology. The seventh awardee of the AIP Founders Award is Llewelyn Stephens, FAIP, Senior Packaging Technologist, LION. The honour was awarded for Llew’s commitment and significant contribution to the promotion and application of packaging technology and education in industry. Llew is highly respected as a packaging technologist and has a sound knowledge of packaging. He is a person of integrity, brings a wealth of experience and understanding, and is always willing to provide counsel and advice to other technologists. AIP Life Member Life Membership of the AIP is designed to recognise those long-standing members who have volunteered their time and passion to the continued growth of the institute. Life Members are people who continually go above and beyond for the AIP and for the betterment of the packaging industry. This year the AIP has one Life Member - Richard Mason MAIP. Richard continues to assist the NSW Division even in his retirement and has worked in the packaging industry for over 40 years. He is on the national membership grading committee, the NSW branch committee and helps the national office on a continued basis. Nothing is too much trouble for him and he is always willing to help the AIP in any way he can. AIP Fellows The grade of Fellow is the highest professional recognition awarded to AIP Members by their peers and is designed to recognise the significant and sustained contribution these people have made to the technology, science or application to packaging in the industry. The AIP upgraded two members for 2012: Dr Roya Khalil, Senior Packaging Technologist, SPC Ardmona and Nola Porteus, Paper & Board Laboratory Manager, Visy Technology & Innovation Centre.

PACKAGING

Pictures clockwise from top left: Pierre Pienaar with Llewelyn Stephens, Richard Mason, Dr Roya Khalil and Nola Porteus.

AUSPACK PLUS 2013 Hot and cold glue technology, MAP inline tray sealers and new inkjet technology are just some of the new products that will be showcased at AUSPACK PLUS 2013. The event, which is held from 7 to 10 May 2013 at the Sydney Showgrounds, has companies such as Robatech, Fallsdell, Proseal Australia and Result Packaging confirmed as exhibitors.

Robatech will display its Corrutack-2 and CartoGlue LP products; Proseal is showcasing its range of full vacuum MAP inline tray sealers; and Result Packaging will be exhibiting the new Leibinger JET3 and JET2neo inkjet coders. Fallsdell Machinery Sales Consultant Darren Cameron said that, like other exhibitors, Fallsdell looks forward to exhibiting at the 2013 AUSPACK PLUS. “Fallsdell will once again be exhibiting a great range of our new equipment as well as equipment from our long list of worldwide agencies,” Cameron said. “AUSPACK PLUS is a great opportunity for us to showcase, under one roof, our full range and services to our customers and potential clients.” AUSPACK PLUS is owned and presented by APPMA, the Australian Packaging and Processing Machinery Association. For more information on exhibiting at AUSPACK PLUS, contact Event Manager Luke Kasprzak by phone (02 9556 7972) or email (LKasprzak@etf.com.au).

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July/August 2012

>>>

Packaging PACKAGING

NEWS Olive oil producer pays penalty for mislabelled olive oil A South Australian olive oil company has paid $13,200 for two infringement notices for attempting to pass off low-quality olive oil as ‘extra virgin’. The Australian Competition and Consumer Commission (ACCC) issued the Big Olive Company with two infringement notices for labelling nearly 3000 bottles of 500 mL Oz Olio oil as ‘extra virgin’ that the ACCC decreed were not extra virgin quality oil. The oil was tested following complaints from the Australian Olive Association that some olive oils being produced and sold in Australia as extra virgin olive oil are not of a high enough quality to be labelled as such. The ACCC said that “although there is no mandatory standard for extra virgin olive oil in Australia, it is widely accepted that it is the highest grade oil obtained from the first press of the best quality olives”. Extra virgin olive oil should not be blended with other oils and there should be no solvents or refining in the manufacturing process, the ACCC said. The Oz Olio oil tested had more free fatty acids than permitted by olive oil trade standards, including the voluntary Australian standard, suggesting that the olives were old, damaged or poor quality and the oil was not extra virgin olive oil at the time of bottling. The ACCC said it is considering the Australian Olive Association’s concerns about extra virgin olive oil claims and has contacted the association with a view to discussing greater labelling clarity for Australian olive oil. Although the Big Olive Company has paid the infringement notice penalties, the ACCC emphasised that this does not constitute an admission that the company has contravened the Australian Consumer Law.

Improved packaging to enhance shelf life Consumers are demanding more sustainable packaging solutions that also perform shelf-life extensions, while brand owners understand the commercial advantages that active or intelligent packaging technology can deliver to their products. In supply chain research, more work is being done on oxygen scavengers, moisture absorbers and barrier films that will enhance the shelf life of products. Consumers want packaging that keeps products clean and ready for eating, with longer shelf life, product security and value for money. This remains a big ask, but if success is to be achieved, packaging technologists need to rise to these demands. New packaging strategies have been developed to address the challenges of extending shelf life in storage and transport. Modified atmosphere packaging is a technology that attempts to manipulate the atmosphere surrounding the produce in order to delay spoilage. There are different types of modified atmosphere. One method injects nitrogen, carbon dioxide and/or oxygen into packs or containers in order to modify the air surrounding the food. This gas mixture or gas flushed type of system requires that the air surrounding the product be removed and the desired gas mixture is then inserted. The exact concentration percentage of oxygen, carbon dioxide and nitrogen used is dependent on the type of food or produce stored or being transported. The mixture is dependent on the packaging material, product and storage temperature. The gas must be inserted into an airtight enclosure. An alternate and less expensive method incorporates additives directly into plastic films used for covering pallets or lining boxes of produce. Ethylene absorption packaging is a relatively new technology that falls into this category of modified atmosphere packaging methods. Pallet covers with ethylene absorbing technology deliver a higher quality product by minimising the amount of ethylene present during transport and storage of fruits and vegetables. This technology protects produce quality without the need for expensive gas and/or equipment. It is a method that will be closely observed as more is learned about this technique. Pierre Pienaar MSc FAIP Former National President Australian Institute of Packaging (AIP) info@aipack.com.au www.aipack.com.au Ralph Moyle MAIP has been announced as the new National President of the AIP

July/August 2012

www.foodprocessing.com.au

PACKAGING

Hygienic milk powder packing system Chronos BTH has recently installed and commissioned a high-accuracy bagging and palletising system for milk powder sector company Emmi Milch, Switzerland. The bagging system features a hygienic design, accurate operation and an ability to change products quickly, which is vital given the large number of powders to be packed. It was also necessary for Chronos BTH to overcome limited space challenges on the production site. The Emmi factory produces a diverse range of milk powder derivatives, such as whey powders and permeate, all of which are hygroscopic, dusty and sticky; and a challenge to handle. Gerold Schatt, Head of the Dagmersellen factory, said: â&#x20AC;&#x153;We opted for Chronos BTH due to the ground clearance of the filling line as well as the filling and closing concept.â&#x20AC;? An OMLH-1030 BF hygienic bagging system is the key piece of equipment for this project. Its design automatically picks up and places the open-mouth bags, which are multi-ply, cross-bottom bags with polyethylene liners, onto the filling spout. An integral vertical dosing screw ensures that dust emissions are kept to a minimum during both main and fine-feed filling cycles. Filled bags are removed via an indexing conveyor; during this bag transportation phase before it is presented for de-aeration, the bag top remains closed. A combination of de-aeration probes and agitators on the conveyor optimise removal of excess air from each bag. At the next part of the process, the bag mouth is stretched and prepared for sealing, while top air is carefully pressed out of each bag. Bag closure is completed through a combination of impulse heat sealing and the Chronos BTH double fold over tapping system, which complement each other to minimise potential moisture ingress into the filled bags. For additional security, sealed bags pass through integral metal detection and checkweighting systems, with any rejected bags being removed before they enter the gripper head of the specially configured palletiser via an inclined conveyor. The palletiser is rated at 600 bags/h and a series of palletising programs ensures that all of the Emmi bagged products are palletised in the optimum manner to suit their individual requirements. An automatic wrapper completes the automation of the bagging process and it can also offer six different wrapping programs. Currently, the packing system is operating on a two-shift system and is rated at 200 bags/h, packing products with individual filling weights of between 10 and 50 kg. All the equipment is EHEDG (European Hygienic Engineering & Design Group) compliant and all of the processing modules are designed to provide Emmi with optimum filling accuracy in a hygienic and cost-effective manner. Chronos BTH is a subsidiary of Premier Tech Ltd. Chronos BTH http://www.chronosbth.com

July/August 2012

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Black ink for thermal ink jet Domino Printing Sciences water-based BK651 black ink for thermal ink jet (TIJ) applications was developed specifically to withstand the rigours of the pharmaceutical market. It has been awarded a grade A through to Blue Wool 4 during independent testing and evaluations on printed samples of the ink to establish its performance and light-fastness, undertaken by international packaging, paper and print-industry specialists PIRA International. Samples of 2D data matrix codes printed by Dominoâ&#x20AC;&#x2122;s BK651 ink were tested against samples produced using other market-leading inks to assess fading characteristics. Both of these samples were incrementally exposed to a filtered Xenon arc light source to Blue Wool 5 in compliance with ISO 105-B02. This is considered to represent the worst-case lighting that is likely to occur in a retail environment. After each exposure, the legibility of the data matrix code was assessed and a measurement of the colour difference was taken relative to unexposed print samples. The results concluded that, of the samples provided to PIRA, the water-based black

Inkjet coders with automatic nozzle sealing The Leibinger JET3 and JET2 Neo inkjet coders offer automatic nozzle

ink maintained a grade A through to Blue Wool 4 and softened to a grade B at Blue Wool 5. Typically, packaged medicines and healthcare products within the pharmaceutical industry have to withstand significant wear, from being stored in distribution hubs for periods of anything between five and 24 months, or being subject to the stresses of global transportation. At the end of these processes, itâ&#x20AC;&#x2122;s vital that the product codes are still readable and conform to the top-quality grade A for light fastness.

sealing that closes the nozzle and

insignia Pty Ltd

return line airtight after shut down.

Contact info and more items like this at wf.net.au/Q402

Drying and clogging do not occur due to the closed ink circuit. Leibinger claims that no cleaning is required; no flushing takes place so consumables are not wasted as the printhead remains closed after use. The oscillator technology in the printhead is shockproof and provides reliable marking even in poor conditions. Fast with multiline text, the units print contactless on a range of products. The short ink drying time enables immediate handling of the products. The Windows operating system uses functions such as drag and drop and pull-down menus, meaning users can create print jobs quickly and easily. Being a compact unit, the printhead can be integrated into existing production lines, where space is restricted. The solid stainless steel cabinet, colour touch screen and printhead have been designed for long-term industrial use, both for hygiene in the food sector and for use in harsh environments. The systems are user-friendly, with a colour TFT touch display for handling. The refill system allows for neat refilling of ink and solvent. The JET3 and JET2 Neo systems can be used with the JETMotion automated traverse system and the JETVisio camera vision system.Â Result Packaging Pty Ltd Contact info and more items like this at wf.net.au/N945

A Food Standards Agency UK research study, contracted by Pira International during November 2008 to April 2011, has developed screening tests for visible and non-visible set-off. The project developed a scanner for measuring the total surface area of patches of visible set-off on the food contact surface of packaging, and exposure techniques and analytical methods which allowed the measurement of individual ink components on the food contact surface of packaging. The extent of migration of these ink components from packaging into food was also quantified.

ÂŠiStockphoto.com/ Dmytro Kozlov

PACKAGING

Measuring the migration of ink in packaging

Results and findings

The first part of this project successfully developed a scanner capable of detecting and measuring visible set-off on the food contact surface of packaging. The scanner would be suitable as a quality control test for regulators and the food packaging industry to measure set-off. The second part developed exposure techniques and analytical methods for the measurement of individual

Reprinted with permission from The Food Standards Agency, UK, an independent government department set up by an Act of Parliament in 2000 to protect the public’s health and consumer interests in relation to food. http://www.food.gov.uk/science/research/contaminantsresearch/contactmaterials/a03prog/a03projlist/a03069/

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July/August 2012

PACKAGING

et-off is defined as: “The unintentional transfer ink components which may be present on the food conof substances used in printing inks from the tact surface of packaging, as a result of set-off. The ink printed (outer) surface of materials and articles components were photoinitiators and synergists. A list of intended for food packaging to the inner food commonly used photoinitiators and synergists was estabcontact surface.” lished to create a library to enable the identification and As a result of the finding of 2-Isopropylthioxanthone measurement of the compounds looked for in this work. (ITX) in drinks packaged in multilayer cartons, most likely Having developed exposure techniques, the next phase of as a result of set-off, ink suppliers are now introducing this project successfully developed a procedure for measurpolymeric photoinitiators (used in printing inks to speed ing non-visible set-off (that cannot be seen by the naked up the drying process of the ink using ultraviolet light) eye) using extraction solvents. The measured set-off was and synergists (which take part in the reaction involving not always the same along the length of a roll of printed the photoinitiator) as partial or complete replacements for film. There was no significant effect on the set-off results monomeric photoinitiators and synergists. There is very obtained after storage or in the different extraction solvents. little published data on the extent of transfer of these new Similarly, the application of pressure had no significant compounds to food contact surfaces via set-off and their influence on results. While it was not possible to replicate subsequent migration into food. the storage pressures packaging may be subjected to on a The aim of this Food Standards Agency, UK, project roll in a factory setting, and it was not always possible was firstly to further develop screening test procedures to replicate ‘real-life’ conditions in the laboratory, results capable of measuring the extent of visible set-off (which tended to demonstrate that set-off is not a food safety iscan be seen by the naked eye) of these replacements sue because of the low levels of printing ink components and other ink components to the food contact surface of found to set-off from the prepared films. packaging. Secondly, exposure techniques and analytical Finally, migration experiments were undertaken on a methods to quantify individual variety of foodstuffs using the ink components on the food specially prepared test films. contact surface of packaging These films contained known The project will enable laboratories to identify printing were developed to allow the ink compositions at levels ink components on unused food packaging, estimate measurement of non-visible higher than would be expected worst case migration and thereby assist in the prevention set-off. Finally, the migration of in commercial applications. of packaging transferring components to foods at ink components was measured The objective was to promote in a variety of foodstuffs from set-off to test the developed undesirable levels. specially prepared test films. method and allow comparison The project will enable laboof data. Migration often apratories to identify printing ink components on unused food proaching 100% across the range of ink components was packaging, estimate worst case migration and thereby assist measured in a variety of foodstuffs. Significant migration in the prevention of packaging transferring components to (30 to 50%) was also observed into ‘Tenax’, a dry food foods at undesirable levels. simulant. Food simulants are used in the laboratory to mimic the characteristics and properties of foods. The Research approach developed procedure for testing printed packaging can be The objectives set in this project were to: carried out within one working day to assist laboratories • f urther develop the technology produced in a previous in identifying photoinitiators and synergists on unused Agency project (A03010/11/12); packaging and estimate worst-case migration for shelf-life • d evelop a test procedure for visible set-off; applications of six months or longer at room temperature. • d evelop suitable (non-dietary) exposure techniques and This work concentrated on method development and did analytical methods to enable identification and quan- not test examples of actual food packaging. It is intended tification of ink/varnish components; in collaboration for the methodology to be discussed with relevant stakewith industry produce reels of packaged printing with holders and used to inform future work on food packaging inks/varnishes of known composition and quantify the where set-off could occur. extent of set-off; This research fits into the Food Standards Agency’s stra• m easure the extent of migration of selected components tegic aim of ‘safer food for the nation’ and its objective of into food; and use the results of the above to develop improving food safety by ensuring that the food produced a rapid screening method for set-off. or sold in the UK is safe to eat, by tackling contamination in the food chain.

PACKAGING

System upgrade for tea grower Established in 1929, BOH Plantations in Malaysia account for 70% of all tea produced in Malaysia. With four tea gardens encompassing 1200 hectares, its annual production is around 4 million kg, translating to about 5.5 million cups a day. Being one of the few vertically integrated tea companies in the world, BOH Plantations has operations ranging the entire spectrum of tea manufacture - from cultivation and processing to the packaging and marketing of its range of black teas. The company is accredited with ISO 22000 certification. In order to maintain its prime position in the domestic retail market and expand into overseas niche markets, the company recently invested in its manufacturing process. The ‘key’ performance requirements for the equipment upgrade were: product quality, production flexibility and space utilisation. The processing systems needed to be state of the art, with exemplary hygienic manufacturing and quality standards (homogeneity, product safety, cleaning ability). The manufacturing operation was to be designed to allow multiple recipe production simultaneously this technique is sometimes known as ‘parallel processing’. Quick recipe changeover and cleandown (where necessary) also had to be considered. BOH wanted to use existing floor space for the new production area, which should allow for future expansion both in capacity and number of recipes being produced. BOH has fully adopted Matcon’s ‘lean manufacturing’ philosophy of parallel processing in its new production facility. By installing a Matcon Cone Valve Intermediate Bulk Container (IBC) System, BOH has a flexible manufacturing facility, maximising throughput with minimum equipment investment. By operating independent ‘process modules’ and using the IBC as the ‘vehicle’ to move the product, overall equipment effectiveness (OEE) can be optimised, lowering the cost per kg produced. The Matcon Formulation Bay (housing four major ingredient IBCs) doses the major ingredients automatically using Cone Valve technology in a gain-in-weight manner into the receiving batch IBC at floor level. The major ingredient IBCs

on the formulation bay can hold a combination of several recipes without the need for changeover. Due to the quick and accurate discharge achieved with Matcon Vari-Stroke Discharge technology, there is no requirement for a secondary feeder. This makes the system easy to clean and allows for minimal downtime when ingredients need to be changed. Minor ingredients are preweighed manually and added into the Batch IBC. Keeping this task manual provides high flexibility as there are many variations of minor ingredients. Formulation of the batch time is also shortened as this operation is done in parallel to the major ingredient batching. BOH selected a Matcon IBC Blender as it achieves homogenous blends for a wide range of recipes using its 360º tumbling action. Many factors were evaluated including flexibility and product quality. As the IBC is the blending vessel, no cleaning of the blender unit is required (the IBC is cleaned offline), therefore the blender can mix several recipes without the need for cleaning and with zero contamination risk. This blender allows BOH to increase product quality, mix multiple recipes without any downtime and utilise minimal floor space. A Matcon Discharge Station is installed above each packing line ensuring a controlled discharge without product segregation, maintaining the homogeneity of the blended product. This is again achieved with the use of Matcon Cone Valve Technology. To meet the demands of today’s volumetric fillers, the powder handling (refilling of the infeed hopper) became even more important. If refilling is not reliable and ‘steady’, the product bulk density will change (head load in the infeed hopper), affecting the accuracy of the filled sachet and speed of the machine. By using Matcon Cone Valve Technology, BOH achieve the desired throughput rate of the packer while maintaining product quality. The system was installed in March 2011 and is now operational, and furthermore meets all of BOH Plantations performance requirements. Matcon Pacific Pty Ltd Contact info and more items like this at wf.net.au/Q391

Control & Power Switches Extensive Range of

Stainless Steel & Insulated Enclosures

www.krausnaimer.com.au Adelaide Sydney Melbourne Brisbane Tel: (02) 9797 7333 Tel: (03) 9720 9777 Tel: (07) 3252 8344 Tel: (08) 8371 1443 Fax: (02) 9797 0092 Fax: (03) 9720 9766 Fax: (07) 3252 1497 Fax: (08) 8371 0901 Linked with an Australian Wide Distribution Network

July/August 2012

www.foodprocessing.com.au

Pre-dosing filling system To enable juices consisting of sacs, fibres, fruit chunks or pulp to be filled as gently as possible, Krones separates the juice from the fruit content itself, both in the process engineering for thermal treatment and in the filling technology downstream. To assist with

PACKAGING

the process, the company has created a pre-dosing filler called FlexiFruit for the fruit particle content before the actual juice-filling carousel in the main filler. The purpose of the filling process is to run hot pre-dosing into the containers of a fruit-fibre or fruit-chunk mixture with a fruit content of around 50% in chunks measuring up to 10 x 10 x 10 mm in size and 50% juice, before the actual free-jet hot filler is reached. Up to now, piston fillers have mostly been used for this purpose; the trouble is that they are not able to be cleaned in place, or not completely. Post-dripping may impair the accuracy of the dosing function, which is why the company has developed a simple, hygienic system thatâ&#x20AC;&#x2122;s easy to clean; one that, if at all possible, no longer drips after dosing. A solution featuring diaphragm valves was chosen, which offers the additional benefit of minimising the damage rate. One of the systemâ&#x20AC;&#x2122;s major advantages is that the dosing filler itself does not need to possess an additional measuring instrument. What happens is that the entire fill quantity is measured in the downstream weighing-cell filler, where the juice without any fruit cells is bottled. High priority was also given to ensuring operator-friendly maintenance. By developing the FlexiFruit pre-dosing system, Krones has closed the circuit required for holistically gentle production of beverages with a fruit-chunk content. Krones (Thailand) Co Ltd Contact info and more items like this at wf.net.au/Q385

DFC Packagings Range Of End Of Line Equipment.

DFC Packaging Vic. 20 Summit Rd Noble Park , 3174 03 9701 2000 sales@dfc.com.au www.dfc.com.au

July/August 2012

DFC Packaging NSW. 21/197 Power St Glendenning, 2761 02 9625 0266 sales@dfc.com.au www.dfc.com.au

www.foodprocessing.com.au

Frozen cubes for smoothies Chefs Pride has launched Smoothie Cubes, fruit- and vegetable-filled frozen cubes

INGREDIENTS

for making smoothies. Users simply add 200 mL of milk or fruit juice, blend and serve. They reduce the problems associated with fruit seasonality and are claimed to contain all natural ingredients. The cubes have been developed by dietician and nutritionist Joanne Turner and are suitable for use in the healthcare, education, cafe, catering, mining, hotel and armed forces sectors. The company claims their ease of use, nutritional value, portion control and convenience makes them suited to a range of food service operators. Seven flavours are available: Berry Antioxidant, Tropical Buzz, Brekkie Anytime, Bananaberry Blast, Mango Banana Tango, Fruit & Veg Antioxidant and Vegie Shot. The cubes come in 1.5 kg packs of 40 cubes. Each pack makes up to 20 smoothies. Chefs Pride Contact info and more items like this at wf.net.au/Q210

Echinacea and Pelargoniumbased ingredients The Frutarom immune health portfolio includes highly bioavailable forms of minerals such as copper and zinc, as well as Echinacea and Pelargonium-based ingredients. Echinacea EFLA 894 is a dry-pressed herb juice traditionally used as an immune tonic and to treat cough and cold symptoms. Frutarom claims its Pelargonium EFLA 956, a root extract from Pelargonium sidoides DC, is a safe and effective product that can help speed recovery from cold and flu while reducing the severity and duration of the associated symptoms. Both products are produced under strict PIC-GMP certification guidelines and in line with ecological principles, the company says. Almost all of the ingredients are available as water-soluble powders and contain minimal or no trace of carrier. They are suitable for use in a range of finished dietary supplements and pharmaceuticals, such as tablets, softgels, syrups, bars, shots and candies. Frutarom www.frutarom.com www.foodprocessing.com.au

July/August 2012

No-fat, low-fat dressings don’t get most nutrients out of salads ©iStockphoto.com/Angelika Schwarz

INGREDIENTS

Brian Wallheimer

The vegetables in salads are full of vitamins and nutrients, but you won’t get much benefit without the right type and amount of salad dressing according to a recent Purdue University study.

n a human trial, researchers fed subjects salads topped off with saturated, monounsaturated and polyunsaturated fat-based dressings and tested their blood for absorption of fat-soluble carotenoids - compounds such as lutein, lycopene, betacarotene and zeaxanthin. Those carotenoids are associated with reduced risk of several chronic and degenerative diseases such as cancer, cardiovascular disease and macular degeneration. The study, published early online in the journal Molecular Nutrition & Food Research, found that monounsaturated fat-rich dressings required the least amount of fat to get the most carotenoid absorption, while saturated fat and polyunsaturated fat dressings required higher amounts of fat to get the same benefit. “If you want to utilise more from your fruits and vegetables, you have to pair them correctly with fat-based dressings,” said Mario Ferruzzi, the study’s lead author and a Purdue associate professor of food science. “If you have a salad with a fat-free dressing, there is a reduction in calories, but you lose some of the benefits of the vegetables.” In the test, 29 people were fed salads dressed with butter as a saturated fat, canola oil as a monounsaturated fat and corn oil as a polyunsaturated fat. Each salad was served with 3, 8 or 20 grams of fat from dressing. The soybean oil rich in polyunsaturated fat was the most dependent on dose. The more fat on the salad, the more carotenoids the subjects absorbed. The saturated fat butter was also dose-dependent, but to a lesser extent. 32

July/August 2012

Monounsaturated fat-rich dressings, such as canola and olive oil-based dressings, promoted the equivalent carotenoid absorption at 3 grams of fat as it did 20 grams, suggesting that this lipid source may be a good choice for those craving lower-fat options but still wanting to optimise absorption of health-promoting carotenoids from fresh vegetables. “Even at the lower fat level, you can absorb a significant amount of carotenoids with monounsaturated fat-rich canola oil,” Ferruzzi said. “Overall, pairing with fat matters. You can absorb significant amounts of carotenoids with saturated or polyunsaturated fats at low levels, but you would see more carotenoid absorption as you increase the amounts of those fats on a salad.” The findings build on a 2004 Iowa State University study that determined carotenoids were more bioavailable - absorbed by the intestines - when paired with full-fat dressing as opposed to low-fat or fat-free versions. Ferruzzi; Wayne Campbell, a Purdue professor of nutrition science; Shellen Goltz, a Purdue graduate student in food science; and their collaborators, Chureeporn Chitchumroonchokchai and Mark L Failla at Ohio State University, are the first to study different types of fats in differing amounts in human subjects. Ferruzzi and colleagues will next work on understanding how meal-patterning affects nutrient absorption. He is trying to determine whether people absorb more nutrients if they eat vegetables at one time or if consumption is spread throughout the day. Purdue University www.purdue.edu

www.foodprocessing.com.au

Tocopherol replacement product Vitiva has launched Substar, a rosemary-based, oil-soluble oxidation management

Vitamin B formulations for dietary supplements

system. Substar is an alternative to tocopherols for protecting shelf life in a variety of products. Substar is designed to be used with a range of sensitive applications and products

LycoRed has developed formulations designed

such as edible fats and oils, fish oils, vegetable omega oils, margarine, pet food,

for hair and nail nutrition based on vitamin B

animal feed and cosmetic oils. It does not need to be combined with any other

complex and amino acids. The systems are made

ingredients to be effective.

using LycoRedâ&#x20AC;&#x2122;s microencapsulation technology. Vitamins such as thiamine (B1), riboflavin (B2) and biotin, along with choline, can benefit hair and nails. Deficiencies can lead to loss of hair Combining different nutrients with diverse organoleptic properties in dietary supplements is not always easy, due to undesired aromas or flavours, such as vitamin B1 and methionine. Microencapsulation can mask these unwanted aromas and flavours. LycoRedâ&#x20AC;&#x2122;s formulations are suitable for manufacturers of dietary supplements. The company

While tocopherols are not heat stable and so are not suitable for foods that undergo

claims microencapsulation improves the flowabil-

heat treatment, Substar is highly heat stable, and is also light in colour. The com-

ity and direct-compressible nature of B-vitamin

pany says the product is highly deodorised and has reduced bitterness and flavour.

amino acids. The product is reportedly stable in both tablet

According to the company, side-by-side testing using Rancimat methodology showed that Substar demonstrates greater activity and protection factor than delta-

and hard-shell capsules.

tocopherols, the most potent tocopherols.

LycoRed

Ingredient Box

www.lycored.com

Contact info and more items like this at wf.net.au/Q150

www.foodprocessing.com.au

July/August 2012

INGREDIENTS

and weak, brittle nails.

INGREDIENTS

A $10 million purposebuilt mushroom facility was recently opened at Parwan, west of Melbourne. Fresh food producer Perfection Fresh Australia and asset management company Mecrus have partnered to form Parwan Valley Mushrooms, which will produce 50 tonnes of commodity mushrooms a week. The facility was designed and constructed by Christiaens Group, the world’s largest supplier of turnkey mushroom farms, and features a multiple climate control system and a fully automated under-bed irrigation system. Parwan Valley Mushrooms will produce about 2600 tonnes of mushrooms a year, mostly white Agaricus bisporus mushrooms, including buttons, cups and flats. According to Parwan Valley Mushrooms CEO Tim Adlington, the facility is considered a medium-sized farm in a global sense, but incorporates cutting-edge mushroom farm technology. “The world’s most advanced mushroom farm technology, design and construction expertise resides in Holland. Australia does not have the specific design and construction expertise to deliver this type of facility,” Adlington said. “However, regional Victorian companies were contracted to provide associated infrastructure including earthworks, plumbing and electrical requirements during construction.” Michael Simonetta, CEO of Perfection Fresh, said Mecrus ran a feasibility study that showed mushroom production in Australia is a significant horticultural opportunity. “There has been an upside in the demand curve for mushrooms Australia-wide in recent years due to a combination of factors, including effective promotion of the mushroom category by the Australian Mushroom Growers’ Association (AMGA) and growing general awareness about the health benefits and versatility of mushrooms,” Simonetta said. “Demand continues to exceed supply for most of the year and we believe the market is well placed to accommodate Parwan Valley Mushrooms’ products, which will account for approximately 6 to 7% of total Australian production in its first year.”

July/August 2012

www.foodprocessing.com.au

Ingredients NEWS

$10m mushroom facility opens in Victoria

Junk food advertising and food security: latest ANU poll results More than 75% of Australians believe junk food advertising should be banned during children’s television programs and 18% believe junk food advertising should be banned completely. These are some of the findings of the latest Australian National University (ANU) poll, Public Opinion on Food Security and Related Food Issues. ANU researchers said that while 37% of respondents can afford to eat out more than once a week, up to 16% of respondents have concerns about their food running out before they have enough money to buy more. Additionally, 13% felt they could not afford to eat nutritionally balanced meals and 4% had received emergency food assistance in the past. Responses to genetically modified (GM) food were mixed. Up to 44% of those surveyed felt that GM foods are safe to eat, but among those who have researched GM foods, only 49% feel GM foods are safe to eat. Despite these responses, 54% of all respondents said they were unlikely to buy foods labelled as genetically modified. Food safety was another issue that elicited a range of responses. While 81% felt food products in general are safe to eat, nearly two-thirds don’t trust food products imported from Asia. The poll, the twelfth run by ANU, was conducted by Professor Stewart Lockie, Head of the School of Sociology, and Dr Juliet Pietsch, from the School of Politics and International Relations.

Third-party audits and food safety Part I: What can go wrong will go wrong

processed on another, packaged on yet another and then shipped and sold all over the world. This has led to new logistical challenges and an increase in risks to both consumers and global brands. An incident in any part of the supply chain can have legal, brand and even criminal repercussions for the food brand names.

o help mitigate such risks and to have better product traceability and control over their supply chain, many manufacturers and retailers have implemented a range of food safety management systems standards and schemes, many of which have been independently certified. For most of the world, this has driven continual improvement, helped mitigate risks, led to increased efficiencies across the supply chain and helped suppliers reduce costs. However, in the US, two food safety crises over the past three years have led certain interested parties to question the role and even complicity of both the second- and third-party certification industry in managing risks in the food supply chain. To help put into context where we are today, we should revisit a particular incident that occurred on 13 January 2009. On that date, the Peanut Corporation of America issued a recall for products it had made over the past six months, after five people had died and more than 400 had fallen ill with Salmonella poisoning as a result of contamination. Two weeks later, the recall was extended to more than 400 consumer products made since 1 January 2007, while the toll from the contamination had reached eight dead and more than 500 sickened in 43 states, half of them children. The companyâ&#x20AC;&#x2122;s factory in Blakely, Georgia, which was the source of the contamination, supplied some of the largest food makers in the US. The outbreak illustrated the complexities of the industrial food chain and left consumers scrambling to figure out if the food in their cabinets posed a danger. The Peanut Factory Salmonella crisis led to a fundamental review of the approach to food safety in the US. The crisis was directly linked to the US Governmentâ&#x20AC;&#x2122;s Food and Drug Agency (FDA) and its impossible task of inspecting the plethora of US food organisations. Media articles, including an in-depth one in The New York Times, highlighted the failures in the auditing process, the lack of relevant experience of the auditor and auditing company as well as the lack of

a robust standard against which the audit was carried out. The article was accompanied by a range of supporting material that included insight from key food safety stakeholders, each stating what they thought was wrong with the inspection approach to auditing in the US food supply chain and outlining possible solutions. Out of this crisis came a new FDA plan, one which recognised the need for best practice and more knowledgeable, better skilled auditors. Addressing best practice, the FDA studied the approach to food safety taken by Australia, Holland and other nations that were considered to be more successful in mitigating food supply chain risks. To address the limited resource issue, the FDA installed a system that gave preferential treatment to organisations that could demonstrate a voluntary commitment to third-party inspection through independent audits and reports. Note the word inspection here, as that was the part of the approach that remained unchanged after the FDA review post Peanut Factory crisis. This fact would come back to haunt the food sector less than three years later. Fast forward almost three years and, once again, third-party auditing was at the centre of a food safety crisis in the US. Between September and December of 2011, a cantaloupeborne Listeria outbreak killed 30 people, the deadliest foodborne illness outbreak in the US in over 25 years. As well as the deaths, 146 people became ill and a pregnant woman miscarried. A US federal investigation into the cantaloupe Listeria outbreak found that the farm that produced them had ignored government safety guidelines. FDA officials who visited the Jensen Farms facility stated that the outbreak could have been prevented if Jensen Farms had maintained its facilities in accordance with existing FDA guidance. They found 13 samples of Listeria monocytogenes obtained from processing equipment and cantaloupes and www.foodprocessing.com.au

July/August 2012

PROCESSING

The global food supply chain has become increasingly complex. Raw materials are grown on one continent,

Addressing best practice, the FDA studied the approach to food safety taken by Australia, Holland and other nations that were considered to be more successful in

PROCESSING

mitigating food supply chain risks.

cited several deficiencies in the Jensen Farms facility, such as dirty water pooling around the food processing equipment, inappropriate food processing equipment which was difficult to clean and no antimicrobial solution in the water used to wash the cantaloupes. The congressional investigation report notes that Bio Food Safety, a subcontractor for Primus Labs, a third-party food safety auditor, which was hired by Jensen Farms, gave the facility a 96% rating, “despite finding several major and minor deficiencies”. Bio Food said the audits only deducted from the score if a method or technique was inconsistent with FDA regulations, but not if FDA guidance was not being followed - hence the rationale behind the high ratings. What is apparent is that the Jensen Farms audit was a ‘checklist approach’ and not a process-based audit, which looks at the whole series of interacting processes that form a management system. In parallel, and from widely available reports, it appears that the auditor from the subcontracted firm to Primus had little or no food sector experience, which only added to the problem, raising even more questions about the 96% rating awarded to the site. If you are starting to think “wait a minute, haven’t we been here before?”, you are not alone. Both of these seismic events have highlighted weaknesses in the US approach to food safety. These incidents demonstrate how much is still left to do in order to mitigate food supply chain risks; how important experienced, competent, qualified auditors are in

the assessment and certification process and the importance of moving away from snapshot-in-time style audits towards a process-based management systems approach that looks at the systems and processes that organisations have in place. What steps should the FDA, as the government organisation that can single-handedly influence the behaviour of organisations across the food supply chain, now take? A start could be the acceptance and even insistence on industry-developed, globally accepted standards and schemes. Following the Global Food Safety Initiative (GFSI) lead, FSSC 22000 and ISO 22000 could be a very good starting point. The FDA has hinted at an accreditor-type role (in other words, they would be the gatekeeper for auditing bodies, ensuring that only competent auditors with relevant sector-specific experience are performing audits). Further, this would hold certification bodies and registrars to a higher level of scrutiny and transparency than is currently the case. That, in turn, would help build confidence in the assessment process and in the resulting certificate. Ensuring the effectiveness of the systems and processes that govern an organisation and making sure that risks are properly assessed and managed, that is the true value of independent assessment. Parts II and III of this article can be found on www.foodprocessing.com.au Lloyd's Register Quality Assurance Contact info and more items like this at wf.net.au/Q409

Weigher range for handling granular products Ishida has launched a range of high-speed Cut-Gate weighers for handling granular products which can be easily damaged by auger or volumetric cup fillers. The range has a weigh hopper that minimises the discharge time of the weighed product without spillage, along with a Cut-Gate mechanism that the company claims improves product feeding and offers a faster processing capability than the previous version. The weigher delivers up to 30 weighments/min/head, depending on product type, Ishida claims, while maintaining good accuracy and gentle handling. The weigher is suitable for a range of granular products including detergents, freeze-dried coffee, tea and other drink granules, sugar, salt and couscous. The servomotor-powered gate offers a gentle but precise opening and closing profile which controls product feeding to preserve particle size and structure while reducing dust emissions. Easy to operate, clean and maintain, the weigher has quick product changeovers to minimise downtime. The dustproof construction has weighing components that are enclosed in an easily detachable cover. A sealed enclosure for gas flushing is also available. The range comprises 10 different models that can be designed to meet product, pack and line requirements, in addition to the 14 models available in the standard Cut-Gate weigher range. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/N786

July/August 2012

www.foodprocessing.com.au

Slicing cheese with automated precision

PROCESSING

New Zealand boasts a world-class dairy industry with annual exports in excess of NZ$11 billion. This success can be largely attributed to technological advances in both farming practices and manufacturing techniques. Key strengths of NZ’s dairy industry include its all-grass farming system, large-scale processing and high levels of R&D. With a reputation for providing products that comply with rigorous health and safety standards, the NZ dairy industry is forecast to benefit from continued growth and productivity for many years to come. Cheese production is one of the most complex in the dairy industry, involving a variety of processes to achieve the final product. Automating processes in cheese manufacture can i mpro ve a manufacturing plant’s productivity to meet increasing demand. Accurate control and customisation of manufacturing processes is necessary for optimal large-scale quality cheese production. Skilled engineers and technologists are required to designing manufacturing processes to produce consistent product characteristics that meet customers’ expectations. Advances in process and motion control technology have allowed processes that have historically been manually operated in a cheese manufacturing plant to be automated, improving efficiency and safety. When an international cheese manufacturer decided to automate its cheese slicing processes, it called on Cheese Solutions New Zealand Ltd (CSL), a leading New Zealand OEM machine builder, to design a system to meet its specific requirements. CSL utilised the design capabilities of longstanding system integration partner Integrated Automation Ltd (IAL) to develop a solution that would meet the manufacturer’s requirements. Recent advances in motion control technology take cheese slicing to a whole new level. The project requirement was to take an industry-standard block of cheese and slice it to specified dimensions and weight. When looking for products on the market that could achieve this, IAL decided to use the control processor capabilities of ControlLogix from Rockwell Automation. The challenge was to provide the customer with a complete cheese-slicing production line that could take a 20 kg block of cheese and pass it through a number of machines to break it down into smaller blocks which would then be sliced to form the end product: a slice of cheese measuring 90 x 90 x 2.5 mm. The solution lay in providing precise, high-speed synchronised motion control. An important part of this was accurate control of the portioning process to ensure the product was cut accurately with minimal wastage. According to Stephen Cotter, Solutions Architect - Motion Control, Rockwell Automation, “While the

July/August 2012

rest of this plant utilises product solutions from Rockwell Automation, this new machine required additional motion control capabilities.” The new L73 processor, which has faster processing capabilities and improved motion control, was used. “It’s certainly the processor for the job because it’s up to speed to control the motion at the cheese-slicing business side,” continued Cotter. The application depends on precise motion control and timing. The block of cheese has to be indexed precisely because the slicing is performed with a rotating knife. Movement of the cheese and rotating blade needs to be coordinated as the speed at which the cheese must move is dependent on the density, weight and size of slice required. To achieve this, ControlLogix required a sample code with a particular CAM profile that the Rockwell Automation OEM team developed in Singapore. ControlLogix provided the single control platform with RSLogix5000 design and configuration software. “In addition to the advanced control capabilities required, building this machine also required a comprehensive mechanical design to ensure the machine’s mechatronic system is reliable enough to carry out the tasks of slicing the product,” said Donovan Ryan, Director, IAL. “There was no other choice but to go with the new L73 processor in this high-speed motion application; every millisecond was critical.” Safety was also a consideration. The mechanical design of the cheese-slicing machine ensures the rotating blade was protected from operator access at all times. Maintenance requirements were minimal as the engineers were already familiar with the Logix technology. The cheese slicer provides the manufacturer with the flexibility to adjust the cheese’s thickness automatically. By checking the weight, the thickness of the slice can be adjusted by changing the CAM profile to account for the density of the cheese. “This solution provides the customer with the ability to accurately perform to the required velocity with the ease of integration using RSLogix5000 motion control commands,” said Cotter. As consumer demand increases, automation and process technology help improve productivity in the cheese industry. The benefits of automating the cheese manufacturing plant extend beyond the amount of product on the supermarket shelf. Establishing clean, efficient and automated processes minimises wastage of natural resources while providing industry with a way to meet increasing customer demands for quality dairy products. Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q296

www.foodprocessing.com.au

Getty Images

Total food safety confidence with NEVASTANE

TOTAL NevAsTANe food grade lubricants For food safety and dedicated services.

Ensure total food safety for your customers with NEVASTANE Food Grade lubricants. TOTAL goes the extra mile, providing optimum protection and long service life for your equipment, with enhanced security and efficiency. All NevAsTANe Lubricants are NsF H1 registered.

For more information or to locate your nearest TOTAL lubricants distributor: Phone Toll Free: 1800 TOTAL OIL (1800 868 256), email: lubricants.au@total.com or visit: www.totaloil.com.au

The right choice in lubricants

Photoelectric sensor The ifm efector OG-Cube photoelectric sensor has a robust metal housing with a 2-wire output stage. The minimum

PROCESSING

leakage current of 1.7 mA means the photoelectric sensor can be used in normal AC power mains at 20 to 250 V AC. The sensor is suitable for harsh industrial environments. The technology in a compact

Fanless waterproof panel PC Interworld Electronics’ APC-3591 stainless steel fanless waterproof panel PC is sealed to IP65 specifications on all sides. All external I/O, including the DC power input, serial, ethernet and USB ports have waterproof sealed connectors.

and robust housing provides good flexibility when used in adverse applications where space is restricted. Due to a minimum drift when light and dark objects are detected, the sensor is claimed to achieve long ranges which remain constant even with coloured backgrounds. Additionally, the operation of the sensor is colour independent for greyscale and black values. Additional features include good repeatability and fixed ranges for a quick set-up. The OG-Cube can be supplied as through-beam sensor, retro-reflective sensor and diffuse reflection sensor with background suppression. A range of mounting accessories are available for universal mounting. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q111

Dry-running rotary screw compressor range

The PC combines an emPC

and

15″

Kaeser has introduced a range of dry-running rotary screw compressors, the CSG-2 series. Available

bedded

with drive powers ranging from 37 to 90 kW, these two-stage machines provide free air deliveries

350 cd/m2 LCD in a thin IP65 stain-

from 4.8 to 12.7 m³/min for pressures between 4 and 10 bar (g). Together with the existing DSG-2

less steel enclosure measuring

and FSG-2 series, Kaeser’s dry-runner range covers free air deliveries from 4.8 to 50 m³/min, or

399 x 324 x 72 mm. The panel PC

even or 51.8 m³/min with variable speed control.

supports Intel Core 2 Duo 1.66

CSG-2 systems are suitable for applications where dry compression is required. Users can choose

or 2.26 GHz processors and up

between air- and water-cooled versions and also have the option of SFC variable speed control for

to 4 GB of 800/1066 MHz DDR3

applications with fluctuating air demand. The air-cooled systems are designed for use in ambient

memory. The 15″ LCD provides a maxi-

temperatures up to 45°C. Each unit contains a quality, two-stage compressor airend. The rotors are equipped with Ultra

mum resolution of 1024 x 768

Coat, which can withstand temperatures up to 300°C. The coating is also abrasion-proof. Kaeser

pixels and is available with an

claims its dry-running rotary screw compressors consume no more energy after years of use than

optional analog resistive touch

when first commissioned.

screen. External I/O includes two

The PC-based Sigma Control 2 internal controller combines multiple control modes, a timer and

USB 2.0 ports, two COM ports,

base load sequencing to provide energy savings. The system provides flexibility through its numer-

one RJ45 LAN port and one audio

ous interfaces and plug-in communication

Its wide range DC input

control systems, computer networks and/or

(11 to 32 VDC) allows the PC

remote diagnostics and monitoring systems,

to be powered from most DC

such as Kaeser’s teleservice facility.

sources. The PC is suitable for

CSG-2 systems have a large display, SD

and marine environments.

by IE3 premium-efficiency motors and have

Interworld Electronics & Computer Industries

motor winding temperature, which enables maximum motor switching frequency and reduces idling periods. Kaeser Compressors Australia Contact info and more items like this at wf.net.au/N891 July/August 2012

industrial process control, medical

card slot and RFID reader. They are powered PT100 sensors for measuring and monitoring

line-out connector.

modules, enabling easy connection to master

www.foodprocessing.com.au

Contact info and more items like this at wf.net.au/N824

PROCESSING

Steam sterilisation system for decontaminating spices, herbs and seeds The Ventilex continuous steam sterilising system is designed for the high-temperature/ short-time (HTST) decontamination of spices, herbs and seeds. The system can treat a range of products from powders to whole spices. Product is fed through a high-pressure rotary valve that isolates an autoclave from the ambient room. Inside the autoclave, a shaking table transports the product being processed in a chamber that is pressurised with steam that kills pathogens and bacteria. The product is discharged through a second rotary valve and into a fluid bed dryer where the condensed moisture is driven off. The product is then returned to the original moisture level or dried to the desired moisture level. The steriliser is available in three standard throughput sizes: 0.5, 2 and 4 m 3 of product per hour. Multiple continuous autoclaves can be arranged to feed one dryer system. Components are controlled by an accurate and repeatable PLC and all parameters are logged in a data logger, ensuring valid data of treatment can be recalled when required. The system has a sanitary, clean-in-place design. Brolton Group Contact info and more items like this at wf.net.au/Q378

Process valve control head Bürkert’s Type 8681 Control Head, integrating pneumatic actuation, feedback, diagnostics and fieldbus interface, has been engineered to assemble with all commercially available hygienic ball valves, butterfly valves, single-seat, double-seat and mix-proof valve configurations. The Type 8681 offers the same control features as Bürkert’s Element angle-seat, globe and diaphragm valves. Designed for use in hygienic processes in the dairy, food/beverage, biotechnology or pharmaceutical industries, the 8681 head has a smooth and chemically resistant IP65/67 enclosure that is easily cleaned and suited to use in washdown areas, Bürkert claims. Internally, the contactless internal positioning system reduces internal wear and the pneumatic

Centrifugal compressor

pilots have manual overrides. Super-bright LED position indication is

Centac centrifugal compressors are

designed to be visible from across the

oil-free single- to multi-stage compres-

plant floor. The green, amber and red

sors which provide high-quality, clean

LEDs indicate valve switching position

compressed air to Class 0 certification

or maintenance/fault requirement with

for a range of industrial processes.

status/colour settings customised via

The most recent model, the C1000, is

DIP switch. This is suitable for use in

claimed to be the most efficient.

dairy and food/beverage plants, where

Its design has been simplified so

process machinery often spans a wide

that efficient operation is achieved even

distance or stretches above walkways.

in harsh Australian operating environ-

The 8681 control head controls strokes

ments, the company says. It is suitable for use in applications where high volumes of

up to 85 mm with three positions with

compressed air are required, such as smelting, mining and food or chemical processing.

200 L/min pneumatic air for each pilot

The compressor has a main compressor unit and three coolers mounted on a cast-iron

valve and is certified for explosive

frame. The three coolers - two inter-stage and one after-cooler - have been oversized

environments, with ATEX Cat. 3, Zone

to provide greater resistance to fouling and also to provide low CTD and pressure drop

2/22. Other inclusions are: automatic

to increase compressor efficiency and reliability. Heavy-duty, high-efficiency motors and

configuration ‘teach-in’ software, which

uniformed hardened components are claimed to improve durability and reliability.

autocommissions the control head; the

The vertically split arrangement of the compressor’s design provides quick access to

ability to adjust chamber switching speed

major components of the compressor. Cleaning the water tubes involves a simple pro-

individually in both directions of move-

cess of removing the two end covers of the cooler to clean out any debris in the tubes.

ment; and a non-return valve to prevent

In the fully enclosed model, all components are mounted in an acoustic enclosure that only requires water, power and air connections. CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/Q248 44

July/August 2012

www.foodprocessing.com.au

faulty switching due to back-pressure. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/N900

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 92 convenient locations Nationally, all IS09001:2008 accredited

Rick Robinson

PROCESSING

Robotic system automates poultry deboning process

A robotic system used in the Intelligent Cutting and Deboning project prepares to slice through the shoulder joint of a chicken. The system, developed by the GTRI Food Processing Technology Division, is pursuing two goals: cutting close to the bone to maximise breast meat yield and ensuring food safety by avoiding creation of bone chips.

Researchers at the Georgia Tech Research Institute (GTRI) have developed a prototype system that uses advanced imaging technology and a robotic cutting arm to automatically debone chicken and other poultry products.

July/August 2012

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PROCESSING

he Intelligent Cutting and Deboning System employs a 3D vision system that determines where to cut a particular bird. The device automatically performs precision cuts that optimise yield, while also greatly reducing the risk of bone fragments in the finished product. “Each bird is unique in its size and shape,” said Gary McMurray, chief of GTRI’s Food Processing Technology Division. “So we have developed the sensing and actuation needed to allow an automated deboning system to adapt to the individual bird, as opposed to forcing the bird to conform to the machine.” In the Intelligent Cutting and Deboning System, a bird is positioned in front of the vision system prior to making a cut, explained GTRI Research Engineer Michael Matthews. The vision system works by making 3D measurements of various location points on the outside of the bird. Then, using these points as inputs, custom algorithms define a proper cut by estimating the positions of internal structures such as bones and ligaments. “Our statistics research shows that our external measurements correlate very well to the internal structure of the birds, and therefore will transition to ideal cutting paths,” Matthews said. “In our prototype device, everything is registered to calibrated reference frames, allowing us to handle all cut geometries and to precisely align the bird and the cutting robot. Being able to test all possible cut geometries should enable us to design a smaller and more simplified final system.” The prototype uses a fixed two-degree-of-freedom cutting robot for making simple planar cuts. The bird is mounted on a six-degree-of-freedom robot arm that allows alignment of the bird and cutting robot to any desired position. The robot arm places the bird under the vision system and then it moves the bird with respect to the cutting robot. The system employs a force-feedback algorithm that can detect the transition from meat to bone, said Research Engineer Ai-Ping Hu. That detection capability allows the cutting knife to move along the surface of the bone while maintaining a constant force. Since ligaments are attached to bone, maintaining contact with the bone allows the knife to cut all the ligaments around the shoulder joint without cutting into the bone itself. A similar approach can be used for other parts of the bird where meat must be separated from bone. Hu explained that the force-feedback algorithm uses a force sensor affixed to the knife handle. During a cutting operation, the sensor enables the robot to detect imminent contact with a bone. Then, instead of cutting straight through the bone, the system directs the cutting tool to take an appropriate detour around the bone. “Finetuning is needed to adjust the force thresholds, to be able to tell the difference between meat, tendon, ligaments and

Gary McMurray, Chief of the Georgia Tech Research Institute’s Food Processing Technology Division, poses with the Intelligent Cutting and Deboning System, which uses advanced imaging technology and a robotic cutting arm to automatically debone chicken and other poultry products.

The device automatically performs precision cuts that optimise yield, while also greatly reducing the risk of bone fragments in the finished product.

bone, each of which have different material properties,” Hu said. McMurray said he expects the Intelligent Deboning System to match or exceed the efficiency of the manual process. Testing of the deboning prototype system, including cutting experiments, has confirmed the system’s ability to recognise bone during a cut and to avoid bone chips - thus demonstrating the validity of GTRI’s approach. “There are some very major factors in play in this project,” McMurray said. “Our automated deboning technology can promote food safety, since bone chips are a hazard in boneless breast fillets. But it can also increase yield, which is significant because every 1% loss of breast meat represents about $2.5 million to each of Georgia’s 20 poultry processing plants.” Georgia Tech Research Institute www.gtri.gatech.edu

www.foodprocessing.com.au

July/August 2012

Automated pressure calibrator The ConST 811 automated pressure calibrator is a compact, lightweight calibrator that can generate from 90% vacuum to +25 bar (375 psi). It is suitable for field test, service and commissioning applications. The easy-to-use calibrator can automatically provide the required pressure with a control stability of 0.005% FS and accuracy of 0.02% FS. The unit has a large, easy-to-read display with a 7â&#x20AC;ł colour

PROCESSING

screen and an intuitive icon-driven menu structure for device under test and task selection. Hart communications is supported and a 24 VDC loop power

Pressure sensors with IO-link ifm efectorâ&#x20AC;&#x2122;s robust pressure sensor now communicates all data flexibly via switching outputs or IO-Link 1.1. Process data and diagnostic information are trans-

is provided, as well as reading the current or voltage of the pressure transmitter or transducer under test. With optional external pressure sensors, the calibrator can measure pressures up to 700 bar (10,000 psi) with 0.025% accuracy.

mitted easily using a standard cable. Also, parameter

A rechargeable battery gives 8 h of operation between charges

setting of this PN7-type pressure sensor also uses

and the internal memory stores 120 tasks. Full docu-

the IO-Link communication technology. An IO-Link

menting facilities are available. The unit has a leak

master saves the parameters of the connected sensor and transmits them when the sensor is replaced by a device of the same type. This eliminates the need for a new parameter setting. If the IO-Link function is not

test/switch test facility. Zedflo Australia Contact info and more items like this at wf.net.au/Q251

used, then the pressure sensor operates as before, with two switching outputs (SIO mode) or a switching output and a diagnostic output. Additionally, the sensor has high switch point accuracy and switching frequency, as well as being robust. The overload-protected ceramic measuring cell withstands more than 100 million switching cycles, the company claims. Versions with pressure ranges between -1 and 600 bar are available. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q141

X-ray inspection system for harsh washdown environments Eagle Product Inspection has launched the Eagle Pack 400 HC, an energy-efficient X-ray inspection system designed for easy and efficient cleaning in the harsh washdown environments of the packaged meat, poultry and dairy industries. The system may facilitate compliance with food safety standards regarding plant hygiene. The system is constructed of stainless steel plates cut and welded together, rather than bolted, making its design more sanitary by eliminating food debris collection points. It can withstand the repeated use of harsh chemical cleaners and pressurised water. Interlocked hinged louvres can easily be lifted to allow access to the conveyor, reducing the time and labour needed for daily sanitising and assembly. The hinged louvres may decrease the possibility of damaging or losing equipment pieces during cleaning shifts. The 400 HC is designed with an energy-efficient, water-cooled heat exchanger, rather than a separate air-conditioning unit to cool the system, which also results in a smaller footprint on the production line. Its knurled end drive roller, responsible for the motion of the conveyer, incorporates v-grooves to increase the traction of the conveyor belt so it retains its position even if wet or greasy, from cleaning or opened products, says Eagle Product Inspection. Food Processing Equipment Pty Ltd Contact info and more items like this at wf.net.au/N883 48

July/August 2012

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K-Tron

The key ingredient for success, no matter what your process recipe calls for.

From chocolate chips to fiberglass, floodable powders to waxy liquids, K-Tron provides unparalleled reliability, pinpoint accuracy and consistency. `Ê ÕÌÊ ÜÊ /À ÊV> ÊÃ ÛiÊÞ ÕÀÊ >ÌiÀ > Ê > ` }Ê> `Ê vii` }ÊV > i }iÃ°Ê6 Ã ÌÊÕÃÊ>ÌÊÜÜÜ° ÌÀ V> °V °

7 Ê /Ê ,-ÊUÊ Ê6 /Ê / ,-ÊUÊ 6 ,/ ,Ê6 6 -ÊUÊ6" 1 /, Ê , "--Ê Ê7 /ÊUÊ,"/ ,9Ê ," " -

Brolton Group Pty Ltd

69 Princes St, Riverstone, NSW, 2765, Australia Sydney Ph: +61 2 98381311 Perth Ph: +61 8 6263 4426 Fax: +61 2 9838 3113 E: sales@brolton.com.au

www.brolton.com.au

Modular valve and block system Burkert has released a modular valve and block package that it says is designed to help build systems quickly and easily. The Inox system incorporates a stainless steel pneumatically actuated valve and standard block modules

PROCESSING

with eight standard port channels. The ports are drilled open in accordance with block channel design, bolted together and valves screwed in to complete the block system. Strainers, check valves and sensors are easily included in block construction, the company claims. The system supports media to 180Â°C, 16 bar and 600 mm2/s viscosity and has high chemical resistance for process media such as water, alcohols, oils, fuels, hydraulic fluids, salt solutions, alkali solutions, organic solvents, steam and air. The company says the system configuration eliminates the use of elbows

Earmuff for food-processing environments Designed for noisy food-process-

and t-adapters and minimises con-

ing environments, the 3M Peltor

nections to avoid leaks and deliver

H9A-02 Food Industry Earmuff

good overall system performance.

offers Class 5 protection (SLC80:

A small footprint, flexible configura-

26 dB).

tion and fast assembly make Inox

The earmuff combines a range

systems suitable for manufactured

of hygiene solutions for workers

blocks, including temperature systems

who move between areas of dif-

for injection moulding or die-casting

fering temperatures. The foam

tools, chemical dispensing in water

inserts make cleaning simple and

or mineral processing, steam steri-

prevent the build-up of condensa-

lisation systems and other solutions

tion and heat.

requiring high system capability and environmental integrity. The Inox is suited to distributing, collecting and mixing systems with individual valve flow of up to 2.4m3/h. The cast 316L stainless steel body has integrated, self-adjusting packing glands to give good media tightness over the service life. The externally piloted valves have a compact design and are available with threaded, external threaded and welding connection ports. Inox valves, block modules, bushing and other elements are cast 316L stainless steel, with PTFE valve seals and graphite gaskets.

The headband cushion is easy to clean and has no hidden crevices where bacteria can thrive. In keeping with the food and beverage industryâ&#x20AC;&#x2122;s recognised colour for safety products, the earmuff is blue in colour. The earmuff is suitable for a range of food processing environments, such as glass bottling lines, milling operations and baking, dairy and confectionery industries.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/N932

3M Australia Pty Ltd (Occupational Health & Safety) Contact info and more items like this at wf.net.au/Q387

July/August 2012

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Online colour measuring system Bestech has introduced an online colour measuring system: the colorCONTROL ACS 7000 from Micro-Epsilon Eltrotec. It is suitable for: automotive paint inspections; interior colour measurements; forensics; plagiarism detection; processing of plastics, wood, veneers and textiles; and in printing and medical technology.

PROCESSING

The measuring principle is based on an accurate method of colour measurement - spectral imaging - where the spectrum of reflecting light is compared to the white light reference that is illuminated on the measuring target. The system supports three operating modes and the colour value resolution exceeds ∆E 0.01 for a spectral resolution of 5 nm. The first mode measures the colour difference ∆E to the reference value. A maximum of 15 learned reference colours can be stored. The second mode measures the sample's reflectivity spectrum. The third mode measures colours and displays them in the relevant colour space (XYZ, L*a*b*, L*u*v*). The results are used to calculate CIE-xy colour coordinates for wavelengths of 390-780 nm. Observation characteristics such as illumination source (A, C, D65, D50, D75, E, F4, F7, F11 or customised) and 2°/10° standard observers can be adjusted. In addition, users can display and track a trend analysis of ∆E / ∆L*, ∆a*, ∆b* for the individual colours over any period of time. All modes support measurement speeds of up to 2 kHz. The system works contact-free for a distance of up to 55 mm with a measuring geometry of 30°/0°. The system supports online and offline measuring and is operated via a web browser that also displays relevant measuring parameters, including a black/white balance feature. Process interfaces such as Ethernet/EtherCAT, RS422, USB and Digital I/O are included. Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/N965

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July/August 2012

Non-contact switch with magnetic integrated latch The Allen-Bradley 440N-Z SensaGuard non-contact switch with a magnetic integrated latch combines a non-contact interlock switch and door latch into one integrated solution. It can be used to replace separately mounting an interlock switch and door catch in lightweight guard doors. The switch has RFID technology for coding, inductive technology for sensing and output switching signal device (OSSD) safety outputs. It is available with a coded sensor and actuator to help protect against operators or maintenance personnel defeating the switch, helping to improve safety.

PROCESSING

The switch is suitable for machines where multiple access doors must be monitored up to PLe, SIL 3, Cat 4. It does not require a dedicated safety controller for its RFID coding security and so can be connected to a range of standard safety controllers such as Allen-Bradley Guardmaster safety relays, SmartGuard 600 and Safety I/O Blocks. Multiple actuator sizes from 15 to 25 mm allow for a large sensing distance. Both plastic and stainless steel versions carry an IP69K rating and come with electronic short-circuit and overvoltage protection built in. The switch’s PLe, SIL 3, Cat 4 rating is maintained even when multiple units are connected in series. LED indicators give a visual indication of door status, can indicate door misalignment and offer diagnostics to help identify faults. The switch can be connected in series with other devices such as light curtains, e-stops and interlock switches. For increased security, a switch’s RFID tag can be individually coded to an actuator so no other actuator can be used with it. Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q316

Dry block calibrator The Isotech Isis dry block calibrator from Zedflo offers operation to temperatures as low as -100°C. It enables users to calibrate temperature sensors such as RTDs, thermocouples and thermistors at low temperatures without the need for a liquid bath. The Isis requires no hazardous fluids, unlike liquid baths, and offers flexibility and portability. It is suitable for calibration engineers working on-site with low-temperature freezers, such as those in pharmaceutical, aeronautical and food environments. Its minimum operating temperature is also lower than stirred liquid calibration baths. The maximum operating temperature is 40°C, which is a little higher than the minimum operating temperature of Isotech Hot Blocks. Users can therefore cover temperatures -100 to 650°C or higher with two Isotech blocks. The Isis has a large insert of 35 x 160 mm, allowing calibration of multiple sensors. For thermal validation applications, an insert with pockets for a reference probe (6.5 mm) and 20 x 3.5 mm pockets for thermocouples is available. This allows a single calibration cycle to validate up to 20 probes at a time. Full support is available, with options for UKAS/ ILAC/NATA calibration. A tutorial on calibration uncertainties and a range of supporting reference thermometers, indicators and software are also available. Zedflo Australia Contact info and more items like this at wf.net.au/Q250 52

July/August 2012

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Compressor range

PROCESSING

Compressed Air and Power Solutions (CAPS) has launched the extended range of Conquest compressors. The available range includes versions with single-phase electric motors, up to three hp, and three-phase motors of 5, 7.5, 10 and 15 hp. Petrol motor compressors range from 5.5 and 20 hp and a 14 hp diesel model is also available. The fuel drive compressors are designed for use in truck mounted applications and remote areas where electricity is not available. Truck mounted and mobile activities include roadside vehicle servicing and repair, chemical spraying and mechanical fruit tree pruning. Electrically driven motors are suitable for use in commercial workshops and other light industrial processes. The extended range also includes one model with a vertical design which was developed for people with a need for air tools but only have access to single-phase power. It is suitable for smaller businesses such as mechanics, panel beaters or farmers that use impact tools. Conquest compressors are dispatched either directly, to special order customers, or to local distributors. CAPS adds the different sizes of petrol and diesel engines to the air receiver and compressor assembly and carries out any custom modification. CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/N880

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July/August 2012

Dishwasher safe keyboard Interworld Electronics has released the EKFT-108 IP67 waterproof USB keyboard for iKey Limited. Designed for clean office and light industrial environments, the EKFT-108 is a completely waterproof full-travel keyboard that the company claims looks and feels like a standard keyboard.

PROCESSING

Firmware upgrade package

Built with a watertight sealing around the electric circuitry and a removable USB protector, the EKFT-108 can be cleaned with spray disinfectants, water submersion or by placing on the top rack of a dishwasher.

To help simplify the calibration of the

The keyboard provides 108 keys that include a 17-key numeric

4th-generation acoustic technology

keypad and 12 function keys. It is supplied with a 1.8 m USB in-

of the Sultan acoustic wave level,

terface cable and is compatible with the IBM PC standard and all

Hawk has announced a firmware

Windows operating systems. The EKFT-108 is a full size keyboard

upgrade package, making start-up simpler. This will allow for up to 22 different applications such as ROM bins,

measuring 447 x 253 x 30 mm. Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/N758

process slurry sumps, primary crushers, stockpile monitoring and positioning that can start up with minimal adjustments. Converting the AWR234SUXXXX Remote Sultan transmitter from a 3-4 wire AC/DC supply to a 2-wire, loop-powered 24 VDC supply, sometimes meant calibration changes to the transducer. With the firmware upgrade, this is now automatically calibrated. Hawk Measurement Systems Pty Ltd Contact info and more items like this at wf.net.au/Q118

Radar-based sensors for collision avoidance The R-GAGE series of radar-based sensors capable of detecting large objects in challenging outdoor situations has been introduced by Banner Engineering. R-GAGE sensors support collision avoidance and vehicle management applications in container ports, traffic and parking systems, manufacturing, mining, materials handling and railways. With expanded distance capabilities, the sensors can detect objects both farther away from the sensor and closer to it (reducing â&#x20AC;&#x2DC;deadâ&#x20AC;&#x2122; zones). The frequency modulated continuous wave (FMCW) radar provides reliable detection in nearly any weather condition and is not affected by rain, snow, wind, fog, light, humidity or temperature. It also detects stationary objects that cannot be detected by Doppler radar. The sensors provide dual-zone signalling to prevent damaging collisions between harbour cranes. They can also increase efficiency of container movement by providing accurate position information to the crane operator. Models are available for long-range (up to 40 m), wide-angle and narrow-beam applications. All feature easy DIP-switch configuration with no PC required. Micromax Pty Ltd Contact info and more items like this at wf.net.au/N886 54

July/August 2012

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Flexible rising main The Aquaplus flexible rising main is available in lengths over 200 m. Constructed of polyurethane with a polyester

PROCESSING

textile internal reinforcement, it offers resistance to high temperatures and acid water. Suitable for irregular wells, the flexible rising main offers reduced vibration and noise and a self-supporting layflat riser. It permits higher water flow in narrow wells. The Series 25 is suitable for high-pressure pumps. It is appropriate for potable water and meets the requirements of Certification NSF 61 and WRAS. The rising main is also available in a Series 10, suitable for low-pressure pumps, which have similar features and applications as the Series 25.Â It is suitable for applications in the agricultural and mining industries, including obtaining underground water, water monitoring and dewatering. Questas Corporate Pty Ltd Contact info and more items like this at wf.net.au/Q117

Stainless steel junction box Turck has introduced a stainless steel version of its junction boxes, designed to provide a robust connectivity solution for corrosive offshore platforms. With FM approval for Class 1, Division 2, Groups A, B, C and D hazardous locations and rated IP67, the junction box gives good performance in areas that present harsh environmental conditions such as dust, water and salt spray. The junction box has a cast 316 stainless steel housing to resist corrosion in salt spray environments, including chloride corrosion, to ensure continuous connectivity operation. Designed for use on offshore drilling platforms and other ocean-bound equipment, the junction box can be mounted directly on the machine in hazardous environments, with no enclosure required. To ensure the device meets industry specifications, the junction box receptacles are also stainless steel and rated IP67 as long as the ports are covered or connected. The junction boxes are available in 6- and 8-port models and can be used with M12 and 7/8â&#x20AC;ł connector sizes. They can also be used with Turck minifast connectors. Stainless steel junction boxes are designed to house existing circuit boards and receptacle housings. The junction box simplifies the connection of multiple field devices for Profibus-PA and Foundation Fieldbus networks. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/Q135 www.foodprocessing.com.au

July/August 2012

Mass flowmeters The FCB300 and FCB350 have been added to the CoriolisMaster family of direct mass flow measurement products, providing accurate measurements of multiple variables with a compact device. The flowmeters measure flow (mass and volume with accuracies to 0.1%), density, concentration and temperature. The double tube design has no moving parts and requires no up or downstream piping. This minimises maintenance and installation space

PROCESSING

and allows retrofitting of older flowmeters in spaces where Coriolis meters couldn’t be used in the past. The design also uses wider inner tube diameters, producing lower pressure drops and higher capacities than mechanical meters. The flowmeters are designed for a variety of flow measurement applications in oil and gas, chemical, power and food and beverage industries. The meters have an optimised sensor with good zero point and temperature stability. A sturdy design and digital signal processing (DSP) technology allows detection of low flow signals and minimises the effects of pipeline vibration and interference. The meter is self-draining so no measuring media residues remain inside, as can be the case in applications with liquids or condensates in gases. The flowmeters are quick to deploy and an easy to use, three button menu and text display reduce installation and training time. The display indicates mass or volume flow rate, percent maximum flow, flow rates in bar graph form, temperature, density and forward or reverse totalisation. Integrated DensiMass software simplifies computations, including direct Brix measurements and Net-Oil or temperature-standardised concentration calculations on large application data repositories. The new meters support pipe sizes from DN15 to DN150 (0.5″ to 6″). Installation length and handling are identical for all models. Contact info and more items like this at wf.net.au/N887

July/August 2012

Emrich and Nemesis Industrial Automation have collaborated to produce a range of checkweighing equipment to complement Emrich’s existing range of packaging machinery. The Nemesis range covers a number of applications from low-speed, low-weight applications where a high degree of accuracy is required, through to heavy products at medium to low speeds. The weighers can be fitted with a variety of reject systems to remove the product from the line quickly and reliably, which Emrich says can improve efficiency. Emrich can also supply weigh label solutions as part of the range. The range can be integrated to Emrich’s vertical and horizontal packing equipment as well as its cartoning and case-packing equipment. Emrich Industries Pty Ltd

ABB Australia Pty Ltd

Range of checkweighing equipment

www.foodprocessing.com.au

Contact info and more items like this at wf.net.au/Q011

Beginner’s guide to cleaning in place

Chris Hoey

PROCESSING Cleaning in place (CIP) is used to clean primary (and some ancillary) plant lines without dismantling the plant. A mix of chemicals, heat and water is used to clean machinery, vessels and pipe work in a one-shot process, where everything goes to drain, or in a recovery system, which recycles most of the liquid.

IP has has been around for about 50 years. It can be a very efficient way of cleaning in hygiene critical industries, such as food, beverage, biotechnology and pharmaceutical. CIP should be used in any industry and plant where hygiene is critical; the process is usually an integral part of established automation systems. However, expanded health and safety/food security compliance is set to make CIP more stringent - which is good given that a shiny surface on the outside of plant is no guarantee of cleanliness on the inside! CIP is principally concerned with soil removal; however, soil refers to anything that should not be present in a clean vessel and is therefore ‘soiling’ the vessel. Soil can cause tainting and can often be smelled. It may be visible (scale, foreign bodies) or invisible in the form of bacteria, such as E. coli, or yeast spores. A CIP process of at least 15 minutes of a suitable chemical (strength dependent on chemical supplier and product) is required to remove vessel soiling.

The CIP process should optimally run between 50 and 75°C, as there is no cleaning advantage to heating beyond 75°C.

Cleaning agents Commonly used chemicals for soil removal include caustic soda (sodium hydroxide NaOH), phosphoric acid (H3PO4) and nitric acid (HNO3) acids, sodium hypochlorite (NaOCl) and peracetic acid (CH3CO3H). Caustic soda is an alkali typically used at 0.5 to 2% volume. It reacts with fats in the soil to soften them for removal. One downside is that caustic soda is not effective for removing scaling. In addition, sequestrants are often added to keep soiling in solution. Phosphoric and nitric acids are used in detergent formulations for scale removal, often at lower temperatures than caustic. These acids must be used with care as they can attack valve and pump seals. They are often used in dairies for one week in every six weeks, to remove milk scale. Phosphoric www.foodprocessing.com.au

July/August 2012

PROCESSING

and nitric acids are frequently used after commissioning, to remove installation debris. Sodium hypochlorite, usually called ‘hypo’, is very inexpensive, which offers a strong advantage. However, it is primarily used for disinfecting because its ability for soil removal is poor. The active ingredient of hypo is chlorine (bleach). When concentrated, this can corrode stainless steel and will attack seals and personnel. It will also taint the process if not carefully rinsed out and is dangerous if mixed with acid as it will form poisonous chlorine gas. Peracetic acid (PAA) is an equilibrium mixture of acetic acid and hydrogen peroxide. It is a powerful oxidising agent with an oxidation capacity higher than sodium hypochlorite and chlorine dioxide, and is comparable to the oxidative capacity of ozone. PAA at 75 mg/L is reported to successfully kill 100% of a 107 cell/mL yeast or bacterial population in 30 seconds.

CIP line and vessel cleaning When cleaning lines in process equipment using CIP, the correct fluid velocity must be achieved to obtain good cleaning. Laminar flow below velocity 1.5 m/s does not give good cleaning characteristics; quite turbulent flow is instead required, at velocities between 1.5 and 2.1 m/s. There is no gain at velocities above 2.1 m/s. In vessel cleaning, two main methods are generally employed: • High-pressure cleaning to remove soil by force, with the vessel surface being sprayed in a series of passes. • Low-pressure cleaning heads that rely purely on chemical action to remove the soiling.

CIP return The majority of problems with CIP can be attributed to poor CIP return. This causes excessive CIP times, excessive use of detergent and heat, and high effluent discharge.

July/August 2012

To overcome these problems, the system for return must quickly and efficiently return the cleaning solutions back to the CIP set. Critical in this is the choice of scavenge pump. Poor scavenge causes back-up of cleaning solution as well as poor cleaning of the lower part of the vessel. In contrast, effective scavenge allows fresh cleaning solutions to contact all vessel walls and carry away soil effectively.

CIP optimisation Most CIP sequences are never altered following installation; they are usually set to ‘defaults’ which are set during commissioning. However, CIP operators can optimise their systems by monitoring a number of key parameters. • At what temperature and concentration (conductivity) are the caustic tanks set? These are often set too high, increasing costs and offering no additional benefits. • Consider the pre-rinse - does it run clear and then keep going? Is the pre-rinse eliminating sufficient residue? Could it operate more efficiently? • Caustic fill - are the return conductivity and temperature transmitters’ settings optimised? Keep these parameters as near as possible to the limiting effective temperature and pressure as higher parameters offer no benefits but cost in resource inputs. • Intermediate rinse - is it removing caustic solution and temperature prior to sterilisation? Optimise volume, velocity and time of rinse. • Sterilisation - what strength is the sterilising agent and how long is the contact time? Avoid wasted resources by ensuring strength and contact are idealised. Finally, all changes resulting from the CIP monitoring process should be documented and validated, to meet statutory regulations and/or specific client requirements. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/N747

www.foodprocessing.com.au

Optical sorter for removing foreign material Bühler’s Sortex E1A optical sorter is designed to remove foreign material from fruit and vegetable packing lines. Based on colour and shape, the sorter identifies foreign contaminants introduced from the field and packaging process, in addition to extraneous vegetable matter (EVM) and colour defects. Placed prior to food bagging or packing areas, the sorter will detect and remove foreign material that was missed in previous processes or which entered the food line during subsequent handling. Packaging materials such as wood from pallets,

Continuous precision slicer

cardboard from totes and plastic from food liners are efficiently removed.

The ETranslicer is suitable for elongated vegetables, fruits and cooked meats and creates flat and crin-

nology to identify contaminants such as light-coloured wood in potatoes, cardboard

kle slices, oval shred, julienne strips and julienne

in carrots, cigarette ends in mushrooms and coloured plastic in vegetable mixes.

cuts. Engineered to produce continuous precision

InGaAs cameras detect energies in the SWIR (short-wave infra-red spectrum). Fro-

slices, the slicer joins the TranSlicer series in the

zen fruit and vegetables absorb energy at specific wavelengths; however, foreign

Urschel range.

materials reflect it, appearing brighter when seen through InGaAs cameras. InGaAs

The slicer’s cutting wheel mount/holder assembly

camera technology therefore detects and removes foreign materials that cannot be

allows simple wheel changeovers and the sanitary

seen in visible wavelengths.

design includes all mechanical components com-

PROfile (shape) technology operates in tandem with the enhanced InGaAs cameras

pletely separate from the food zone.

to remove rejects which may be of the correct colour, but not the correct shape. Typi-

The slicer joins two other models ready to be

cal examples are pods in peas, stems in beans and berries and misshapen carrots.

tested in the Heat and Control test kitchen: the

SMARTeject disposes of any item identified by the cameras as unacceptable via

Comitrol1700 (for particle sizes ranging from

128 pneumatic ejectors. The ejectors fire a jet of air directly at the defect rather

coarse to fine emulsions) and the DiversaCut2110

than at a general area, reducing the amount of quality content lost.

(small footprint unit for crinkle or flat slices, strip

Buhler AG Australia NZ

cuts or dices).

Contact info and more items like this at wf.net.au/Q138

Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/Q103

www.foodprocessing.com.au

July/August 2012

PROCESSING

The sorter is fitted with Enhanced InGaAs (Indium-Gallium-Arsenide) camera tech-

Robot-guided sensors Bestech Australia provides precise yet flexible laser sensing solutions for robot measurement tasks. Non-contact sensors can be installed on a robot arm for dynamic distance measurements and its data guides the tools or devices attached to the robot arms.

Wine barrel cleaning machine As ‘toast’ can be an important factor when making wine, Gamajet has released the GentleJet; a wine barrel cleaning machine that is claimed to provide a thorough clean without damaging the barrel’s toast. Toast is the level of charring applied to a wine barrel

PROCESSING

during construction. As the level of toast can affect the taste and aroma of the wine within the barrel, it is important that it is not damaged or removed. However, tartrates and other soils do need to be removed, leading to a dilemma when the wine barrel needs to be cleaned. Displacement laser triangulation sensors from Micro-Epsilon

The machine uses Gamajet’s rotary impingement technology

Messtechnik are suitable for such tasks. These small sensors

at low pressure (60 psi) to gently scrub the wine barrel’s interior

have integrated electronics. Measuring ranges are from 2 to

and remove tartrates and other soils. The company claims that

1000 mm with fast measuring cycles of up to 50 kHz.

operating at low pressure minimises the cleaning fluid’s impact

For more complex measurement tasks, the gapControl sen-

within the barrel, which minimises the impact on the toast. The

sor can be installed on the arm for measuring various types

gentle cleaning action may prolong the wine barrel’s use by

of gap. Here, gap measurement data is used to guide the

1-2 years, the company says.

robot along the car or for controlling welding robots.

The machine is said to use less time and water than tra-

For detecting paintwork defects on entire car bodies, the

ditional wine barrel cleaners and, as it does not contain a

reflectControl system can be integrated to the robot and, by

pressure washer, repairs and maintenance are reduced. The

using deflectometry, the surface is examined to micrometre

machine does not contain exposed gears, minimising the risk

accuracy, the company claims. A robot continuously adjusts

of cross-contamination.

the position of the system to help complete measurements

The machine is suitable for use on both oak and stainless

within a short time frame.

steel wine barrels.

Bestech Australia Pty Ltd

Spray Nozzle Engineering

Contact info and more items like this at wf.net.au/Q113

Contact info and more items like this at wf.net.au/Q110

July/August 2012

www.foodprocessing.com.au

The PHBOTTLE Project is an international project that aims to produce a biodegradable packaging with antioxidant properties for juice which is made from watewater sugars generated during the production of the juice.

uropean Fruit Juice Association (AIJN) is the rep- of sugars, which in turn are a valuable raw material for the resentative association of the fruit juice industry production of bioplastics (plastics generated from organic in the European Union (EU) and is involved in the waste and therefore degradable). PHBOTTLE Project. The project is planning to deIn its initial phase, the PHBOTTLE project is identifying velop a biodegradeable packaging solution that can be used for microorganisms capable of converting organic residues from the juice industry. The clear goal of the project is to provide wastewater into a biodegradable polymeric material (plastic), sustainable and comprehensive solutions to environmental the PHB (polyhydroxybutyrate). problems of the juice industry - adding value to waste and Once this material is obtained, its properties will be imtransforming it into new materials with new functions. proved in a second phase of the project, with the incorporation Funded by the EU’s 7th Framework Programme, the project of cellulose fibres and ingredients encapsulated with antioxiaims to produce, within 42 months, a new packaging for juices dant properties. The aim is that the product obtained, when which is biodegradable and has antioxidant properties that containing a food, is able to lengthen the life of the food and extend the life of the food. The packaging will be made from therefore increase its marketing and consumption window. sugars and other residues rich In a third phase, this matein carbon, nitrogen and oxygen rial (after strengthening and present in the wastewater from improvement of its properties) This closes the loop - the waste generator becomes the juice industry. will be moulded and then used to the beneficiary of the new package, tailored to the This project will apply the produce bottles of juice. Finally, latest advances in microencapthese bottles will be validated need of its product. sulation, biotechnology and and tested, by filling them with packaging technologies. An infruit juice from the same industry ternational consortium of eight that generates the wastewater. companies and four technology centres, coordinated by Ainia This closes the loop - the waste generator becomes the benefiTechnology Centre, is working on the project. ciary of the new package, tailored to the need of its product. The international consortium includes: Spain: Ainia TechLife cycle analysis nology Centre, Aimplas (Plastic Technology Institute) and Another environmental objective of the project is the life Cítricos y Refrescantes, S.A.; Belgium: European Fruit Juice cycle analysis (LCA) of the new packaging, which is to cover Association (AIJN) and Omniform, S.A.; The Netherlands: all phases of the project. The aim is to determine the enviTNO Technology Centre; Bulgaria: Silvel Limited; Portugal: ronmental impact during the entire lifetime of the generated Logoplaste Innovation Lab LDA; Argentina: National Institute material - from the raw materials used for its production, of Industrial Technology (INTI); Mexico: Mega Empack S.A.; until the moment the final packaging is disposed of, in order Brazil: Logoplaste do Brasil LTDA; and Honduras: Vanguardia to achieve a packaging that is a 100% biodegradable, with SD de RL. minimal environmental impact. Reason for the project The new material will also be applied to non-food packaging, The juice industry consumes a large amount of water, both mainly packaging for pharmaceuticals and cleaning products for cleaning of equipment and facilities as well as for wash- as well as plastics for the automotive industry. ing of fruits, etc. The industry must treat such wastewater that contains huge quantities of organic waste in the form http://www.aijn.org/pages/juicy-news/phbottle.html www.foodprocessing.com.au

July/August 2012

PROCESSING

Juice packaging using wastewater sugar

Stainless steel safety couplings Stainless steel safety couplings from SERTO are colour coded to help prevent mix-ups of coupling parts. The couplings have a compact design, making them suitable for applications where space is limited. Their construction, which has been zero-static optimised, diminishes bacteria growth and enables easy cleaning. In systems with different media that should not be interchanged or mixed together, the shape and colour coding of the safety coupling

PROCESSING

is a useful safety feature. The double coding only permits users to join coupling parts with the same colour markings. A reliable mechanical locking system prevents incorrect configuration of the parts. The safety couplings are suitable for nominal pressures up to 200 bar and a temperature range of -20 to +80°C. SERTO supplies the couplings with a 6 mm SERTO compression ferrule connection with and without valve. Instead of the SERTO tube connection, the coupling and assembly parts can also be combined with female or male adapters. Neuforce Pneumatics Contact info and more items like this at wf.net.au/Q411

Heavy-duty steam pressure cleaner The Aussie Super Indy Mk III heavy-duty steam pressure cleaner is designed for applications where hot water is required to dissolve grease and oil. It is suitable for use in hard and demanding markets like the food industry. The cleaner’s stainless steel cover is a practical replacement for plastic covers that are prone to split if knocked or dropped, the company says. The steamer also has a robust steel chassis and built-in bumper as well as four solid tyred wheels for easy mobility around the factory or yard. The cleaner is available in 240 V single phase and delivers professional cleaning capabilities up to 1500 psi and 120°C steam. A three-phase option is also available for industrial applications with pressures to 3000 psi and

Continuing professional development program for AIFST Exciting developments are happening at the Australian Institute of Food Science and Technology with the organisation expanding into promising new avenues. The newest venture by AIFST will be to develop a continuing professional development (CPD) program to be headed by the recently appointed CPD Coordinator Bronwyn Graham (pictured). “The program will provide valuable opportunities to those desiring to remain current in an industry that is ever evolving,” says Graham. Having completed a Bachelor of Science, Nutrition and Food at Victoria University and Certificate IV in Training and Assessment, she is looking forward to collaborating with the continuing professional development committee. Bronwyn continues her own studies and is currently working towards a Diploma of Education, secondary in general science and home economics. The AIFST has recently launched its highly anticipated Food Australia website showcasing industry news, article and resources - visit www.foodaust.com.au. Newly appointed Business Development Manager Daniel Cervantes, supported by over a decade of experience in sales and marketing, will bring new energy to the role. Daniel will create opportunities for advertisers and marketers to support the new Food Australia website and publications, in addition to the annual AIFST conferences and related meetings. AIFST is offering ‘Innovate to Survive’ - a Masterclass in Innovation (31 Oct to 1 Nov) in Sydney that will draw together current innovation through engaging speakers and interactive workshops. The program will enhance attendees’ knowledge on how to create a culture of innovation by using emerging technology. Innovate to Survive is just one of the many exciting events to take advantage of as AIFST provides the skills to exploit current knowledge and capture future market opportunities. For more details on the AIFST services available to members, please visit www.aifst.asn.au.

flows to 15 L/m. The cleaner has a heavy-duty slow-speed triplex pump run at 1450 rpm which the company claims increases operating life. A timed total-stop device cuts the machine after the operator releases the trigger, saving power and reducing wear on the machine. A micro-leak control shuts the machine down if a leak is detected in the high-pressure system. Low-water and low-fuel cut-outs are also included. Ergonomic dials give the operator variable temperature control up to 120°C. The steam function is useful for dissolving oil or grease, reducing the need for chemicals and detergent. This makes the machine suited to food processing plants where hygiene and chemical contamination can be an issue. A stainless steel coil option is available for hard-water areas. Australian Pump Industries Pty Ltd Contact info and more items like this at wf.net.au/Q012 62

July/August 2012

www.foodprocessing.com.au

Australian Institute of Food Science and Technology (AIFST)

Monitoring program for produce coating dryer JBT FoodTech’s Smart Dryer system for curing produce coatings is an automated monitoring program that works with JBT’s Single Pass Dryer to maintain even heat distribution and improve energy efficiency. Operating a Single Pass Dryer with an integrated Smart Dryer system is claimed to reduce energy use by approximately 20% per year, compared with using a standard Single Pass Dryer only. The system improves maintenance and operation of the Single Pass Dryer by using microprocessor technology that monitors and controls dryer temperature and humidity, air duct controls, temperature sensors, humidity monitors and integrated exhaust volume control provide consistent temperature and humidity levels. A touch-screen user interface offers a visual display of the

Distributed I/O for safety systems

system’s functions and sensors, enabling quick troubleshoot-

Rockwell Automation has upgraded its Guard I/O to provide the benefits

ing and monitor control. The screen displays an image of the

of a traditional distributed I/O for safety systems.

physical dryer layout; corresponding gauges indicate when

The company claims it reduces wiring costs and start-up time for

cleaning is required.

machines and cells, as compared to in-chassis I/O. Guard I/O can

The touch screen has indicators that turn from green to red

be used with any safety controller that communicates on DeviceNet

to easily identify issues, one-touch temperature adjustment and

or EtherNet/IP networks.

a flashing display that alerts to service needs.

Several Guard I/O block variants are available, providing a variety

The Smart Dryer system now comes standard with the Single

of features for both in-cabinet and on-machine mounting.

Pass Dryer, but is also available as an upgrade to existing dryers.

Rockwell Automation Australia

John Bean Technologies

Contact info and more items like this at wf.net.au/Q018

Contact info and more items like this at wf.net.au/Q233

Peak performance from the market leader • Higher productivity, lower cost of ownership • Scalability from 13 litre/hr to 1200 litre/hr flow • Robust and compact direct-coupled design

e nd se a e Com FTPT us at 3018 d# Stan

1300 WMBPUMPS enquiries@wmbpumps.com.au www.wmbpumps.com.au

www.foodprocessing.com.au

July/August 2012

PROCESSING

screen cleanliness, process temperature and exhaust air. Gas

BAKERY, CEREALS & GRAIN

Grains of truth The simplification of complex nutritional messages has resulted in grain foods like bread and pasta becoming the ‘scapegoat’ for weight gain and bloating, despite ample research to the contrary.

he recent What’s to Gain from Grains? report showed that an estimated 26% of Australians are limiting grain foods like bread and pasta to help lose weight, despite numerous studies confirming that wholegrain consumption has a beneficial effect on weight loss. Professor Manny Noakes highlighted the importance of choosing quality carbohydrates, rather than regarding them as a homogenous category. “Cutting out highly refined or fat- and salt-laden carbohydrates is a good idea, but culling high-fibre and low-GI grain foods at the same time is just throwing the baby out with the bath water,” said Professor Noakes. “Studies show whole grains may have a critically important impact on body composition, particularly in being able to reduce abdominal fat,” she concluded. In line with Australian Dietary Guidelines, consumption of three serves a day of cereal foods is recommended for reduced risk of weight gain.

Wheat avoidance and IBS Worryingly, 16% of Australians may be avoiding wheat-based foods, with a significant 35% self-diagnosing, yet Coeliac disease affects just 1% of the population. According to Dr Jane Muir, specialist in nutrition research of carbohydrates, sufferers of bloating and other digestive complaints - often diagnosed as IBS - can gain relief from their symptoms by following a low FODMAP diet, instead of cutting out all grains. FODMAPs are short chain carbohydrates which are poorly absorbed in the small intestine. The term is an acronym, deriving from ‘Fermentable, Oligo-, Di-, Monosaccharides and 64

July/August 2012

Polyols’. Their removal from the diet has been found to have a beneficial effect for sufferers of irritable bowel syndrome and other functional gut disorders. This diet was developed at Monash University in Melbourne. “People who feel more comfortable on a self-managed exclusion diet are most likely experiencing the benefit from reducing their intake of FODMAPs because gluten-free and wheat-free products are naturally low in these type of carbohydrates, so it’s incorrect to blame gluten for their symptoms,” said Dr Jane Muir. “In fact, they may have a specific FODMAPs intolerance,” she added. With one in seven Australians affected by IBS, a low FODMAP diet which includes a variety of grains for health is proving to be a promising solution, alleviating symptoms in 70% of sufferers. However, Dr Muir does not advocate the long-term use of low-FODMAP grain products as they can inadvertently reduce natural prebiotics in the gut and is calling for more research into this area.

Gut health Research from Dr David Topping confirmed that Australia remains in the grip of an Australian fibre paradox: our total fibre intake is high, yet we have the second highest rate of colorectal cancer, killing 80 people every week. Science is now telling us that fibres may be more effective in combination than individually so there needs to be a greater emphasis on eating not ‘more’ fibre, but a diverse range. In practice, this means soluble, insoluble and crucially, resistant starch, which is low in the Australian diet. The current consensus is that carbohydrates and grain foods have

www.foodprocessing.com.au

BAKERY, CEREALS & GRAIN

about staple foods been mistakenly blamed for many digestive problems and weight gain. In fact, grain foods, particularly whole grains, are vital for bowel health and assist in weight loss, particularly abdominal fat loss. Robyn Murray, CEO, Grains & Legumes Nutrition Council, emphasised the importance of eating from all food groups, using scientific evidence as the foundation for good health. “The report and conference provides a vitally important update on the health benefits of grain foods. I hope it helps to diminish some of the misunderstandings of this important staple and encourages healthcare professionals and consumers to choose quality grains as part of their core diet,” she said.

diabetes, weight gain or overall mortality. Assoc Prof Williams concluded, “Consumption of up to 50% of all grain foods as refined grain foods (without high levels of added fat, sugar or salt) is not associated with increased disease risk.” In practical terms, this means one meal a day can be from refined grains as part of a balanced diet. Refined grain foods can contribute energy-giving carbohydrates and protein to the diet, as well as a range of vitamins, minerals and some dietary fibre. Some refined grain foods have a naturally low glycemic index, such as sourdough white bread, pasta and particular long grain rice varieties, making them the preferred choice.

How much wholegrain?

Although the current dietary guidelines recommend consuming a minimum of four serves of grain-based foods a day, with at least half of those being wholegrain, the research shows that most Australians mistakenly believe that the recommendation is only 2.5 serves per day. This is of concern as grain-based foods significantly contribute to iron, zinc, magnesium, thiamine, riboflavin, niacin, folate, fibre, protein and carbohydrate intake. Over the past two years, consumption of bread, breakfast cereals, pasta, noodles and rice has declined while consumption of mixed meals and takeaway foods and snack bars has increased. Almost a third (28%) of grain-based food intakes currently come from mixed meals and takeaway foods, cakes and pastries. This is passing the ball firmly to bakers and food processors to ensure their formulations contain a balance of wholegrain and refined grain ingredients to maximise the health benefits to consumers.

A review of over 130 studies from the last 10 years has reported that people eating up to 50% of their daily grain foods as refined grain foods (without high levels of added fat, sugar or salt) is not linked with increased risk of chronic disease including diabetes, heart disease and cancer. In Australia, the current dietary guidelines recommend “Eat plenty of cereals (including breads, rice, pasta and noodles), preferably wholegrain”; however, they do not provide recommendations about what proportion of grain foods can still be consumed as refined grains. At the Public Health Association of Australia National Food Futures conference last November, Assoc Professor Peter Williams presented the key findings from his scientific literature review paper: What proportion of refined grains can be consumed in a healthy diet? The majority of studies found no associations between the intake of refined grain foods and cardiovascular disease,

Australians missing essential nutrients from diet

www.foodprocessing.com.au

July/August 2012

CSIRO researcher Dr Peter Dodds is developing synthetic rust resistance genes that that could help protect cereal crops from damage by rust diseases. It’s estimated that rust fungi has the potential to cause up to $300 million in losses to the Australian wheat industry each year. Dr Dodds, the new Fellow of the Australian Academy of Science, has been studying how plants’ immune systems can recognise and respond to these rust fungi, in order to develop novel disease-control strategies. “We isolated the first rust avirulence protein and showed that it is secreted into the host plant during infection,” said Dr Dodds, explaining that the avirulence protein identifies the rust fungi as an unwanted intruder to the plant. “We then demonstrated that the pathogen protein triggers immunity by direct proteinprotein interaction with a host resistance protein.” Dr Dodds’ research team is hoping to engineer new recognition capabilities for disease resistance into cereal crops.

Goodman Fielder to close facilities, cut jobs and reduce product range

Bakery

As part of its plans to improve manufacturing efficiency, Goodman Fielder will close three of its bakery facilities, cut 115 jobs and reduce its product range. The company plans to upgrade its Townsville facility to become a hub for the North Queensland region, but will close its Rockhampton and Cairns facilities as a result. The Rockhampton facility will close on 20 July, while the Cairns facility is expected to remain open until Q3 2013. The Whiteside bakery facility in Melbourne will also close in 2013. These changes will bring the company’s total job cuts to 541 this financial year. “This is a difficult but necessary decision to ensure we can create a more efficient manufacturing footprint in our bakery business,” said Pankaj Talwar, Managing Director of the company’s Bakery Category. “We understand the impact these decisions can have on our people and our immediate priority is to ensure that our employees are supported through this process.” The company says all employees from these facilities will be offered redeployment to other Goodman Fielder sites. Those who cannot be deployed will receive full redundancies and help in the form of an employee assistance program, outplacement program and careers workshop. The company will also reduce its current range from 450 to 350 in order to improve efficiency, improve onshelf availability and increase customer satisfaction. Plans are in place to reduce the range by a further 50 products, which will result in an overall 33% reduction by the conclusion of the project. 66

July/August 2012

Grains & Legumes Nutrition Council formed

www.foodprocessing.com.au

NEWS

BAKERY, CEREALS & GRAIN

CSIRO’s rusty research could protect cereal crops

The Grains & Legumes Nutrition Council has replaced Go Grains Health & Nutrition with a new name and logo. The council is a not-for-profit organisation, founded by the Grains Research and Development Corporation and supported by producers and manufacturers in the grains and legumes industries. The rebrand followed a sixmonth review process during which industry and key stakeholders of the incumbent Go Grains were consulted to ensure the change was in keeping with the organisation’s position as the independent voice for grain foods and legumes in health and nutrition. “The new positioning, which is articulated by the name and brought to life in the logo, more clearly represents both grainbased foods and legumes, which we discovered through research was particularly important when communicating with stakeholders and consumers,” said Robyn Murray, CEO of the Grains & Legumes Nutrition Council. “The organisation will continue to review the science and communicate the latest research findings about nutrition and health benefits of grains, grain-based foods and legumes to a range of audiences and encourage consumers to include these foods in their diet. “Only our name has changed. Our vision, values and day-to-day operations remain the same as they have always been,” she concluded. Industry benefits include access to the latest scientific evidence, insights, consumer attitudes and data on grains, grain-based foods and legumes; literature and technical reviews on emerging industry topics; engagement with public health and healthcare professionals, media and consumers; support of education initiatives and exposure at key conferences.

Acrylamide levels in NZ potato crisps reduced: study

Baker Perkins has upgraded its 590 heavy-duty rotary moulder to a TruClean design to comply with the latest industry standards on hygiene. TheTruClean 590 is primarily used for rotary moulding large, difficult products, particularly pet foods, and is stronger and more powerful than a standard rotary moulder to cope with the extra work required to form these products. TruClean criteria include accumulating the minimum amount of debris, good visibility into all areas and being able to clean the machine easily and effectively. Three specification levels allow the machine to meet the hygiene requirements and cleaning methods of individual customers. The rotary moulder is suitable for products that are difficult to make on a conventional moulder. Pet food products are often large and thick, made from developed dough and include abrasive ingredients such as bone meal. They require tight control of process parameters to maintain quality; heavy-duty construction and components are necessary to handle them at high speed. The moulding roll and feed roll have large diameters and the knife assembly is robust and horizontally and vertically adjustable during operation. The TruClean machine has been reworked to meet or exceed rising industry hygiene standards in accordance with the GMA’s 10 Principles of Equipment Design and other relevant industry guidelines. SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/Q131

www.foodprocessing.com.au

July/August 2012

BAKERY, CEREALS & GRAIN

Heavy-duty rotary moulder

Efforts by New Zealand potato crisp manufacturers to reduce acrylamide in their products have been successful, resulting in a two-thirds reduction in acrylamide concentrations since 2006. A recent NZ Ministry for Primary Industries (MPI) report looked at the major contributors to acrylamide exposure in the country. Acrylamide is a chemical that is naturally produced in foods by frying, roasting or baking food at high temperatures. Results from the survey were encouraging, with acrylamide concentrations in potato crisps decreasing significantly from 1570 to 581 µg/kg from 2006 to 2011. Mean concentrations in hot chips and wheat biscuit cereals remained steady from 2006, while oven baked or roasted potato concentrations appear to have increased. The MPI says consumers can reduce acrylamide levels in their food by ensuring flames don’t come into contact with food during the cooking process and by cooking with a heat source above or on the side of the food, rather than below.

NEW White Papers

Colour sensor The Smarteye ColorWise true colour sensor is designed to work as an instrument or spectrometer. According to the

now available online!

manufacturer, it can solve difficult colour applications at higher speeds

TESTING

than colour cameras.

Understanding microscopes

The four-channel monitor provides a visual confirmation of performance without the user having to switch channel selec-

Microscopes - optical devices used to magnify an object in order for the human eye to discern its details - previously consisted of just two elements but have evolved to incorporate multiple features. To review the components, concepts and specifications of this technology, download this white paper now.

tions or touch the sensor. The sensor allows for a range of application solutions and, by providing a choice of speed versus resolution, is claimed to remove the limits that either speed or resolution alone can offer. Users have control over tolerance, light intensity, output configuration (NPN or PNP), timers and input configuration (edge

Eliminate impulse piping, heat trace and purge lines on DP level measurements

or gate). The sensor has four digital and three analog outputs that

Measuring level with differential pressure is a well understood and reliable method, although accurately measuring differential pressure on tall towers and tanks has always been challenging. For information on a possible solution to better enable operators to control tank level and pressure, download this paper.

help to sort products by colour and can determine specific colour signatures. Pryde Measurement Pty Ltd Contact info and more items like this at wf.net.au/Q157

Implementing OEE (overall equipment effectiveness) measures in the packaging hall

Personal protective equipment range

Overall equipment effectiveness (OEE) is a globally recognised best practice measure to systematically improve your processes for higher efficiencies and better productivity - ultimately leading to lower manufacturing costs and higher profitability. This application paper examines OEE metrics and how to capture them â&#x20AC;&#x201C; download now!

Thermo Fisher Scientific has united with Honeywell Safety Products, a manufacturer of safety equipment including eye, face and welding protection, hand and hearing protection, and

Alarm rationalisation

fall and respiratory protec-

Alarm rationalisation is a systematic process to evaluate potential or existing alarms, qualify which are legitimate, specify their design and capture rationales which can be used to guide operator response. This paper describes the SILAlarm solution and other tips for setting up and sustaining an effective alarm rationalisation process.

tion. The companyâ&#x20AC;&#x2122;s respiratory protection provides solutions for a range of respiratory hazards and industry applications. The range includes both disposable and re-usable respirators as well as air-purifying masks and breathing apparatus. Honeywellâ&#x20AC;&#x2122;s eye and face protection range includes safety and laser eyewear, eyewashes and face shields. A range of safety gloves, earplugs and earmuffs is also available. The company provides fall protection products to suit a range of industry applications. Harnesses and lanyards are tested in accord-

For these and more White Paper downloads, visit www.foodprocessing.com.au/white_papers

ance with the guidelines of AS/NZS 1891.1 2007. Thermo Fisher Scientific Contact info and more items like this at wf.net.au/Q119

July/August 2012

www.foodprocessing.com.au

Alternative CL testing gives Woolworths Bunbury faster results for measuring CL. An extensive trial was conducted at Westons Technologies laboratory in Enfield, Sydney, and a study submitted. AusMeat granted the Series 3000 Food Analyser certification approval in March 2012. By implementing the MultiScan, the Woolworths Bunbury plant has improved yield and sped up production. “It would normally take up to seven minutes to complete a Chemical Lean test using the CSIRO’s microwave method, but with the new MultiScan we can get results in under three minutes,” said Jenny Marns, QA Manager at Woolworths Bunbury. “This gives us the ability to give production the results quicker, allowing them to make ‘real-time’ adjustments to the production and consequently giving us better yield management.”

TESTING

A third of all m eat sold i n Woolworths supermarkets in Western Australia is packed at the company’s Bunbury plant. The plant conducts thousands of chemical lean (CL) analyses every year. Finding the traditional microwave methods too timeconsuming, Woolworths gave Next Instruments, an Australian manufacturer of near-infrared analysers, an opportunity to demonstrate the MultiScan Series 3000 Food Analyser. Next Instruments developed calibrations for CL in beef, pork and lamb from 45 to 95 CL using over 1000 meat samples provided by Woolworths’ Bunbury plant. Woolworths was impressed with the MultiScan’s performance, but wanted the analyser to be AusMeat certified. Next Instruments put forward a proposal to AusMeat to validate the instruments’ suitability

Next Instruments Pty Ltd Contact info and more items like this at wf.net.au/Q358

www.foodprocessing.com.au

July/August 2012

Test kit for gluten Arrow Scientific has launched a test kit for gluten, expanding its product portfolio for food allergens. The AgraStrip Gluten G12 is a lateral-flow device for on-site factory testing. The kit uses proprietary gluten detection technology which employs a next-generation antibody called G12 that targets the most immunotoxic proteins for consumers intolerant to gluten. These tests are sensitive and specific but with a simpli-

TESTING

fied protocol users can run the tests on-site at production lines to quickly and simply verify cleaning of equipment and surfaces to prevent gluten cross-contamination. The easy-to-use AgraStrip Gluten G12 kit has an adjustable cut-off level for qualitative screening at either 5, 10 or 20 ppm gluten. Using these gluten strips, users can determine if there is any residual gluten at different production steps or in the final products, allowing an efficient monitoring of critical control points in an HACCP scheme or any other quality management system. Arrow Scientific Contact info and more items like this at wf.net.au/Q315

Yeast and mould detection system for food products Neogen has developed a rapid

Food temperature measuring instrument

method to detect yeast and mould in food products. The companyâ&#x20AC;&#x2122;s

The testo 108 gives quick food temperature measure-

Soleris system detects yeast and

ments in transportation and storage of foodstuffs, in

mould in 48 hours or less, compared

restaurants, kitchens and chain restaurants.

with conventional methods that can

The instrument and probe are both waterproof to

take up to five days.

IP67 standard. The, included, softcase makes the

The system is a rapid optical

device insensitive to moisture and water, testo claims,

method for the detection of micro-

and protects the device from damage and dirt.

bial contamination. The new test is

Thermocouple probes Type T and Type K are in-

claimed to detect one colony forming

cluded and can be stored directly in the softcase. The

unit (CFU) of yeast or mould per vial

probe is easy to clean, requiring only running water.

in 48 hours or less.

The testo 108 has only two buttons, making it

The system may enable users to

easy to use. It conforms to HACCP and EN 13485.

release products more quickly, saving on inventory costs. Soleris also ena-

Testo Pty Ltd

bles users to easily identify, monitor

Contact info and more items like this at wf.net.au/N877

and map problematic spots in their facilities. The system features quick, automated quality-indicator system protocols. In addition to the yeast and mould test, Soleris tests provide total viable count (TVC) results in as little as 6 to

Viscometer series

8 h; conventional methods take 24

The Fungilab viscometer series has updates such as a touch keyboard, which provides an easy

to 48 h. Coliform results can be at-

handle. It also includes updated software that provides more accurate analysis of samples.

tained in 9 to 10 h and E. coli results

The viscometers have visualisation of flow curves and additional options as step, multistep or ramp. The USB connection allows data to be downloaded to any computer. The Alpha Series viscometers allow fast and accurate viscosity readings and are easy to use. The Expert Series allows users to determine viscosity and other rheological features of homo-

take 7 to 10 h. Users can determine lactic bacteria results in 30 to 35 h; conventional methods can take up to five days.

geneous samples. Cell Biosciences Pty Ltd VWR International Pty Ltd Contact info and more items like this at wf.net.au/Q121 70

July/August 2012

www.foodprocessing.com.au

Contact info and more items like this at wf.net.au/Q345

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

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TESTING

What: Foodtech Packtech When: 25-27 September 2012 Where: ASB Showgrounds, Auckland Online registration for free entry: www.foodtechpacktech.co.nz Foodtech Packtech is a must-attend event! New Zealand’s biennial Foodtech Packtech exhibition gives food sector professionals the opportunity to come face to face with the experts behind the key innovations entering the New Zealand and Australian markets. The event will showcase the freshest ideas, latest technologies and the newest developments entering the food technology and packaging technology market from more than 180 prominent suppliers. A series of development and business seminars will also run, and Foodtech Packtech 2012 is endorsed and supported by the Packaging Council of New Zealand, the New Zealand Institute of Food Science and Technology, and Plastics New Zealand. Many exhibitors are keeping secret for now what visitors will see, but some are prepared to offer a teaser or two into the products and services they’ll have on their stands. You can rest assured that there will be plenty of extra-tempting show specials on some of these, too. No matter your business or interest, there will be something to pique your interest at Foodtech Packtech 2012. D&L Packaging’s Digby Morton says visitors to their stand will see a few interesting technologies. “We are offering the latest in shelf life boosting (SLB) technology, including vacuum packaging, tray sealing/packing, skin packing and thermoforming, and the latest tray lidding barrier films. These technologies greatly extend shelf life to most fresh food products, while maintaining the quality and freshness of the food and all without the need of additives. Clearly there are great advantages for both food producers and consumers. “Odour control technology is another area of huge interest to the sector and many others. We have a brand new, never seen before range of products for odour control. This product is an odour absorber unlike anything else on the market. Our product actually absorbs the odour and does not simply mask the odour by creating clouds of perfumed mist. This product can be used in virtually any building, vehicle, rubbish bin or enclosed area where foul odour is a problem and it will not just mask the odour, but absorb it and eliminate it.” Spain’s Hiperbaric will present its complete range of integrated high-pressure equipment for the first time at Foodtech Packtech 2012. “Hiperbaric is a benchmarking and leading global supplier of high-pressure processing (HPP) equipment for the food industry, and is presenting its fully integrated range of machinery at Foodtech Packtech together with its regional partner Scanz Technologies Ltd,” says Tony Rumbold of Scanz. “Hiperbaric is currently the only manufacturer of high-pressure processing machines offering a whole range of integrated equipment. Hiperbaric will also introduce its latest developments and improvements in HPP wear part and spare part design, which are allowing a consistent decrease in cycle and production costs together with a maximisation of the availability of HPP units and diminishing down times.” Another exhibitor, Intralox, understands just how critical reliable conveyance is to food processors, says Tomoko Sacks. “Our innovative conveying solutions for improving food safety, increasing package handling capabilities and increasing productivity have made radical improvements to our customers’ operations. Intralox’s comprehensive approach to food-safe conveyance includes the right choice of belt and components including ThermoDrive and SeamFree beltings that offer the most time-efficient and cost-effective means of ensuring hygienic conveyance solutions: the Intralox FoodSafe Team’s food safety consulting service; hygienic conveyance design guidelines; and thorough cleaning process management support.” Foodtech Packtech is a trade-only event with free entry for those who register online at www.foodtechpacktech.co.nz. XPO Exhibitions Contact info and more items like this at wf.net.au/Q666 72

July/August 2012

www.foodprocessing.com.au

Come and see the latest in food

A.B.N. 22 152 305 336 www.westwick-farrow.com.au Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 Ph: +61 2 9487 2700 Fax: +61 2 9489 1265 Chief Editor: Janette Woodhouse wnift@westwick-farrrow.com.au Publisher: Geoff Hird Art Director/Production Manager: Julie Wright Art/Production: Tanya Scarselletti, Colleen Sam, Jeanette Teuma Packaging Section Editor: Carolyn Jackson Assistant Editor: Alice Richard Circulation Manager: Sue Lavery circulation@westwick-farrow.com.au Copy Control: Mitchie Mullins copy@westwick-farrow.com.au Advertising Sales NSW, QLD - Kerrie Robinson Ph: 0400 886 311 krobinson@westwick-farrow.com.au VIC, SA, WA - Sandra Romanin Ph: 0414 558 464 sromanin@westwick-farrow.com.au NZ - Gemma Burr Ph: 0800 44 2529 Fax: +61 2 9489 1265 gburr@westwick-farrow.com.au USA - Huson International Media East Coast Ph: +1 212 268 3344 West Coast Ph: +1 408 879 6666 ralph@husonusa.com UK - Huson International Media Ph: +44 1932 56 4999 gerryb@husonmedia.com Germany, Austria, Switzerland - Eisenacher Medien Ph: +49 228 249860 info@eisenacher-medien.de Asia - Lachlan Rainey Ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

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March 2012 total CAB audited circulation (Aust + NZ): 6697 readers (90% personally requested) Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP247345/00010 ISSN No. 1039-8414 NOTICE: All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.

List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing

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